Engine for GAZ 66: characteristics, malfunctions and tuning

Short description

The ZMZ-511 engine and its modifications are used for installation on medium-duty trucks, such as GAZ-53, GAZ-66, GAZ-3307. ZMZ-511 is a modernized ZMZ-53a, 53-11. The ZMZ-511 uses an untuned single-tier intake manifold, which leads to flow pulsations that negatively affect mixture formation. Cylinder heads with highly turbulent combustion chambers and helical inlet ports are used. These heads provide a compression ratio of 7.6:1, versus 6.7:1 for older engines. The ZMZ-513 engine is a modification of the 511 designed for more difficult operating conditions (for military equipment, for transporting goods in rural areas and in other difficult conditions). The engine has a number of design differences, such as a specially shaped sump for the drive axle, shielded design of electrical components, etc. The power and torque characteristics are the same. The ZMZ-513 engine is distinguished by its heavy weight - 275 kg.

Engine Features

When modernizing the ZMZ-511 engine, the following design solutions were used:

• highly turbulent combustion chambers are installed;
• screw inlet ports are used for the cylinder head;
• the front support mounting brackets have been strengthened;
• Thornless method of fastening the bearing cap:
• high-strength cast iron was used in the manufacture of the upper compression rings;
• an exhaust gas recirculation system was installed;
• The phases and location of the cams on the camshaft have been changed.

These decisions made it possible not only to preserve, but also to strengthen the main advantages of the ZMZ-511, which are considered to be:

• reliability;
• simplicity of design;
• maintainability.

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Despite this, the engine is currently not installed on mass-produced cars; it is still in demand for replacing power units that have expired their standard period on previously produced cars.

Characteristics of the ZMZ-511/513 GAZ-53, 3307, GAZ-66 engine

Engine GAZ 66 - Design and technical characteristics…

At the Gorky Automobile Plant in 1964, the GAZ 66 truck was developed and put into production. At first, it was equipped with the GAZ 66 engine of the same name, after which it was replaced by the more powerful ZMZ 66-06. Since 1980, GAZ 66 vehicles began to be equipped with ZMZ 511 engines; today, ZMZ 513 engines are installed. The GAZ 66 vehicle belongs to the category of all-wheel drive cargo vehicles. This unique truck continues to be very popular due to its excellent off-road performance.

Technical characteristics of the GAZ 66 engine

The design of the GAZ 66 engine includes a pre-heater of the PZHB 12 brand.

The scope of application of the ZMZ 511 engine and its modifications is medium-duty trucks:

• GAZ-53;
• GAZ-66;
• GAZ-3307;
• GAZ-66-1;
• GAZ-66A, B, D, P, E;
• GAZ-66-01, 02, 03, 04, 05, 11, 12, 14, 15, 16.

Based on the internal combustion engine ZMZ 511, a modification ZMZ 513 was created. This engine model is intended for vehicles operated in difficult conditions:

1. Military equipment.
2. Transportation of goods over rough terrain, etc.

The new power unit has a number of significant differences from the base model:

1. The weight of the ZMZ-513 engine is 275 kg.
2. The engine sump has a different configuration.
3. The working elements of electrical equipment are made in a shielded design.

Design features of the GAZ 66 (ZMZ 511) engine

The gasoline internal combustion engine has a carburetor-type power supply system.

1. Cylinders with a diameter of 92 mm are located at right angles.
2. The distance between the axes of adjacent cylinders is 123 mm.
3. The pistons drive the crankshaft.
4. The engine is equipped with a closed liquid cooling system.
5. The coolant circulates under the influence of a special pump - forced cooling.
6. The lubrication system operates both under pressure and by spraying oil - combined.

The cylinder block is made from AL-4 aluminum alloy casting.

• The cylinder liners are made of special alloy cast iron, the diameter is 100 mm, the height is 153, respectively.
• The liners have lower fixation, the upper part is fixed under the influence of the cylinder head.
• At the bottom there are sealing rings made of copper.
• Thanks to the displacement of the lower part of the cylinder block housing by 75 millimeters relative to the axis of the crankshaft, its rigidity is significantly increased.
• The weight of the cylinder block body part is 44 kg.

Cast iron is used to make the crankshaft. Manufacturing material – high-strength cast iron VCh-50. The supporting main and connecting rod journals are hardened.

• Main journals with a diameter of 70 - 69.9 mm;
• Connecting rod – 60 – 59.9 mm.

In order to reduce the weight of the ZMZ 511 engine, connecting rods made by forging are used. The values ​​of their parameters:

• Length – 156 mm;
• Weight – 0.86 kg;
• The diameter of the upper hole is 25 mm.

• Weight – 0.565 kg;
• Height – 51 mm;
• Diameter – 92 – 91.99 mm;
• The internal diameter of the piston pin is 16 mm;
• External – 25 mm.

Features of maintenance of the GAZ 66 (ZMZ 511) engine

Regardless of which engine is installed on the GAZ 66, it requires mandatory periodic maintenance. The service life of the power unit depends on the quality and timeliness of maintenance activities. The list of engine care requirements includes the following items:

1. When replacing fuel and lubricating fluids, it is necessary to fill in engine oil and gasoline of the recommended brands.
2. During regular maintenance, it is necessary to tighten the cylinder head fastenings (only on a cooled engine).
3. Monitor the operating temperature of the power unit and prevent it from overheating.
4. Check the degree of tightening of the nut securing the exhaust pipe, and if necessary, tighten it to avoid the penetration of coolant into the lubricant.
5. Check piston rings and bearing shells for faults. At the slightest deformation and other deviations from the norm, immediately replace it with new parts.

Before replacing the lubricant, you need to find out which oil is most suitable for the GAZ 66 engine and in what quantity to fill.

For the GAZ 66, ZMZ 511, ZMZ 513 engines, as well as modifications, it is recommended to use the following brands of engine oil:

• ASZp-10;
• M-5z/10A;
• M-6z/10V;
• Mobil Delvac 1330;
• Mobil Delvac MX 15W/40, 10W/30;
• SSPMO;
• Lukoil 15W40.

The volume of lubricant for engines of this line is 10 liters. The engine oil is changed after the next mileage of 6–10,000 kilometers.

The main problems of GAZ 66 (ZMZ 511) engines and their modifications

All internal combustion engines of this series have similar faults and typical problems:

1. Oil drips in the area of ​​the main bearing seal located at the rear.
2. Reduced pressure in the engine lubrication system.
3. Increased engine oil consumption.

If a situation arises when oil consumption exceeds 0.4 liters over a mileage of 100 kilometers, and the instruments show a sharp decrease in pressure in the lubrication system, it is necessary to send the vehicle for diagnostics with subsequent repairs.

Cylinder block

The ZMZ-511 cylinder block is cast from aluminum alloy. Sleeves with bottom fixation are installed on the engines, they are pressed with a head on top, and the sleeves are sealed with copper rings from below. To improve the rigidity of the block, its lower part is located 75 mm below the crankshaft axis.

The sleeve material is special alloy cast iron. The height of the sleeves is 153 mm. Bore diameter – 100 mm.

Fuel system "ZMZ-511"

The fuel system is based on a 2-chamber K-135 carburetor (previously, K-126 carburetors were also used on 3M3-511 (“-513”) engines). The carburetor is installed at the top of the intake manifold. Each of the carburetor chambers supplies the fuel-air mixture to one of the two rows of cylinders. A fine gasoline filter is mounted close to the carburetor. Vacuum is removed from the carburetor for the operation of the distributor and the crankshaft speed limiter. Under the carburetor, in the intake gas pipeline, a vacuum outlet is also provided for the functioning of the crankcase ventilation system.

ZMZ-513: technical specifications, photos and reviews

The Zavolzhsky Motor Plant began its activities in the first half of the 20th century. Based on sales results in 1950, it became clear that there was practically no demand. The motors did not meet modern requirements for installation on heavy wheeled and tracked vehicles. The plant management decided to develop a line of engines for the automotive industry. It was a real breakthrough. After all, it was then that V-shaped cylinders first appeared in the world. Let's look at the main design features of the ZMZ-513, technical characteristics of the motor, advantages and disadvantages.

“ZMZ-511” and “ZMZ-513”: briefly about the main thing

The first production engines of the Zavolzhsky Motor Plant of the 500 series appeared in the late 80s. The 3M3-511 engines for the GAZ-ZZ07 family trucks were developed on the basis of the 3M3-5Z, and the 3M3-51Z engines for the GA3-66 all-wheel drive trucks and PAZ buses were developed on the basis "3M3-66". The 511th and 513th engines have a fundamentally identical design and very similar technical characteristics.

“3M3-511” is a gasoline carburetor eight-cylinder V-shaped engine with cylinders installed at an angle of 90 degrees and an overhead valve arrangement. The working volume of the power unit is 4.254 liters. Its power is 125 horsepower, or 92 kW (at 3.4 thousand rpm). The compression ratio is 7.6. According to modern classification, this engine has an environmental class of “Euro-0”.

The 3M3-51Z engine has the same characteristics, but it has a reinforced design for operation in more difficult conditions. The differences between the 3M3-51Z and 3M3-511 engines are a different configuration of the oil pan, as well as the presence of shielding of the ignition system. The weight of the 3M3-511 motor is 262 kg, the 513th motor is 275 kilograms. Both of these power units are equipped with a clutch housing for the same unified GAZ gearbox.

The “3M3-511” (“-51Z”) engine runs on low-octane gasoline A-76 (currently branded A-80). These engines are suitable for adaptation to operation on gas, when installing a set of gas-cylinder equipment.

General information

After the creation of a V-shaped engine at the Zavolzhsky Motor Plant, orders poured in like a river. This is not surprising, because the engines boasted excellent technical and power characteristics. The 195 horsepower engine was paired with a 3-speed automatic transmission. At the same time, the power unit could consume both diesel and gasoline fuel, which was very convenient.

Thus, we can say that ZMZ-513 engines have become people's favorites. This is one of the most popular and in demand domestic engines, which are even now installed on various heavy equipment. Let's take a closer look at the 513th model, which was considered one of the most successful of its time.

Service

Since the design of the ZMZ 513 engine is similar to the 511, it is serviced identically. Scheduled maintenance is carried out every 15,000 km.

So, in order to increase the resource of the power unit, it is necessary to carry out scheduled maintenance correctly and most importantly on time. Many motorists do not understand what should be included in this process. So, let’s look at what operations are included in scheduled maintenance:

• Replacing engine lubricant.
• Replacing the oil filter element.
• Adjustment of the valve mechanism (every 30,000 km).
• Replacing the air filter (after 25,000 km).
• Diagnostics of spark plugs (every 20,000 km).
• Checking the condition of the gas distribution mechanism (every 30,000 km).

If you look at it, often motorists only change the oil and filter. Valve adjustment is carried out only if a characteristic metallic ringing is already heard.

Repair

Since the motor was developed on the basis of the 511, the problems are the same as those of its older brother. The main problem can be considered the cooling system. By and large, the owners of the power unit are to blame themselves, since they operate the engine on water, which leads to corrosion of the main structural elements. Also, it is worth noting that the weak link of the unit can be called the thermostat and the water pump, which quite often fail.

The disadvantage of the engine is increased fuel consumption. Many motorists have experimented with reducing fuel consumption. The most effective option remains replacing the carburetor.

Engine owners prefer to repair the GAZ 66 engine themselves, but when it comes to major repairs, they cannot do without special equipment. In this case, the power unit is sent to a specialized car service.

Change of oil

Replacing the lubricant in the engine is quite simple. We wait until the engine cools down. We find the drain hole and place a container under it in the size of 10 liters. Typically, the ZMZ 513 engine fits 9.6 - 9.8 liters. Now that everything is ready, you can proceed directly to the work of changing the oil:

1. Unscrew the drain plug.
2. We wait until the oil drains.
3. We tighten the drain plug, replacing the o-ring.
4. Pour oil through the filler neck.

As practice shows, a large number of owners of the ZMZ 513 engine use motor oil marked M-10 or M-10G.

It is perfect for this power unit and has all the necessary technical and physical properties to ensure normal operation and protection of engine parts.

Design features of ZMZ-513

Some industries have special requirements for vehicle cross-country ability. It was in this case that the ZMZ-513 model was installed. This engine was installed on cars such as GAZ-53, 66, 3307, etc. Consequently, this model was suitable for vehicles with medium load capacity. It is worth paying attention to the fact that the 513th was not perfect. It had one rather significant drawback, which caused a lot of trouble during operation. The fact is that the design included a single-tier, untuned intake manifold. This engineering solution led to the formation of flow pulsations during operation of the power unit. This, in turn, negatively affected the quality of the fuel-air mixture.

Buying and replacing an engine

There are cases when the engine is very neglected, and its repair is impractical or simply impossible. A typical example of such a condition would be a broken cylinder block. As a rule, the block breaks due to operating the engine with zero oil pressure. First the motor knocks, and then it can jam. Usually the bottom cover of the connecting rod breaks off, and the connecting rod itself breaks through the block and comes out.

In advanced cases, I change the entire engine. The stores sell motors of various configurations.

Turbodiesel engine for GAZ 3307

The first set includes all attachments - starter, generator, carburetor, breaker-distributor assembly with high-voltage wires. Motors are also sold without attachments, and accordingly, their price will be cheaper.

You can also buy a used engine second-hand based on an ad. With such a purchase, it’s a good idea to get at least some guarantees. The price of such a unit will be significantly cheaper.

You come across a lot of ads for used engines from the GAZ 53 model.

They are almost completely compatible with the ZMZ 511.10 engine, so such a replacement can be safely carried out without fear that the unit may not fit the parameters.

Ready-to-install motor ZMZ 511.10 assembled

Some owners of 3307 dump trucks install a diesel engine instead of a gasoline one. Such a replacement requires quite significant alterations. What changes will need to be made:

• Install another fuel tank;
• Change the electrical diagram;
• Install a completely different exhaust system;
• Re-weld the frame mounts for the new engine;
• Modify the driveshaft;
• Install other engine mounts.

Most often, the D-245 model is chosen as a diesel engine option, which the Gorky Automobile Plant installed on the GAZ 3309 modification.

Technical characteristics of ZMZ-513

The first thing the designers did was to make a specially shaped pallet and shield it using electrical equipment. This made it possible to use the motor in difficult operating conditions. Most often, ZMZ-513 was used on military equipment, agricultural vehicles and small trucks.

As noted above, the design of this engine is quite simple, but extremely reliable. This V8, with a volume of 4.25 liters, produces about 97 kW at 3,400 rpm, which is quite a lot. For those times it was a very powerful unit - 125 hp. With. Of course, modern internal combustion engines have come a long way. Now 300 horses or more are squeezed out of 1.5 volumes. The compression ratio is 8.5, which can be called standard, but the oil consumption is impressive. If recalculated as a percentage of gasoline, it turns out to be approximately 0.5 units. Despite the fact that this engine was one of the last to be produced in the Soviet Union, it is still popular today.

Reviews from motorists and experts

As for the reviews of experienced drivers, many speak positively about this engine. In particular, they note the unpretentiousness of this internal combustion engine and its fairly high service life with proper operation and proper care. ZMZ-513 was boosted many times for use on military equipment. The compression ratio was changed to operate on low octane fuel. All this speaks of the great potential of the Soviet V-8.

Many drivers note that this engine is not without its drawbacks. But it is extremely maintainable. So, if you had all the necessary tools, the problem could be solved in the field on your knees. With modern engines, where electronics are responsible for everything, this approach does not work. In general, the 13th is loved by drivers and many even use it today due to the low cost of maintenance.

Design flaws of the motor

As noted above, this is an extremely reliable power unit, which is designed for operation in extreme conditions. But it also has its drawbacks, which often appear at the most inopportune moment. For example, if the car is placed at an angle, it will be difficult to start the engine. You'll have to constantly apply gas. There is no such problem on a flat surface. Starting when cold is quite a task. If the starter engages and the internal combustion engine starts, then after a couple of seconds it stalls. Idling under such conditions is extremely unstable. It is not recommended to brake the engine, as this leads to popping noises in the exhaust pipe and increased fuel consumption.

Very often the cause of this malfunction on ZMZ-511/513 engines lies in the spider. Its pad is breathable. There is only one recommendation here - replacement. Usually after this all problems disappear, and the power unit begins to work like a clock.

Reliability in simplicity

A high degree of reliability can be achieved in just a few ways:

• use good quality components;
• simplify the motor design as much as possible;
• improve build quality.

What happened in the Soviet Union? The main parts were of fairly high quality. But the fit suffered greatly. Soviet engineers tried to do everything as efficiently as possible so that the engine worked without any problems.

An aluminum alloy block was used as the basis for the motor. Since the engine is V-shaped, it has two cylinder heads with a 90-degree camber. The design provides only one camshaft. The designers placed an intake manifold immediately between the heads. A carburetor, filter and some other auxiliary systems were also installed on it. There is an oil pump in the rear of the ZMZ, and a water pump in the front. The generator and pump operate via a V-belt drive from the crankshaft.

Crankshaft and piston

High-strength cast iron was used as the basis for the crankshaft, which was additionally alloyed with magnesium. With the advent of other engine modifications, the crankshaft journals were hardened. The connecting rod journals have a diameter of 60 mm, and the main journals - 70 mm. Accordingly, the design provided two oil seals: one in front, the second at the rear of the crankshaft. The first was made of rubber, self-clamping type, the second - from asbestos cord.

ZMZ-513 pistons were cast from aluminum alloy. They are quite simple in design and have a flat bottom. The piston diameter is 92 mm, and there are also 5 repair sizes available. Therefore, this motor can be capitalized many times. The piston has three corresponding grooves: two for compression rings, one for the oil scraper.

Engine ZMZ 5231 10

Modern trucks of the GAZ 3307 brand use a gasoline, or scientifically, carburetor engine. This engine is called ZMZ-5231.10.

The most important difference of this modification is the increase in engine capacity to 4.67 liters. The volume increased due to an increase in the piston stroke from 80 to 88 mm.

The cylinder diameter remained unchanged (92 mm), but a different crankshaft and pistons were installed.

Fuel and lubrication system

The first models of this line of engines were equipped with K-126 carburetors, which were later replaced with K-135 due to low efficiency. Many car owners modernize their engine by installing a more economical fuel supply system. Two-chamber carburetors were used, since fuel was supplied to each row of cylinders from a separate chamber. A fine filter was located in close proximity.

A one- or two-section gear-type oil pump is installed on the engine block. Not the most reliable option, but quite productive and maintainable. The pump was driven by the camshaft, and a corresponding oil receiver was used to collect oil from the sump. As for filtering engine lubricant. Over the entire period of operation of this motor, a variety of filters were used. First, a centrifugal filter was installed, then a full-flow filter, and now they use a replaceable filter element, which is extremely convenient and profitable. It is noteworthy that this engine had a very effective system of protection against oil starvation. If the pump stopped, the pin on its drive was cut off, respectively, the entire internal combustion engine stopped and remained intact.

Maintenance and repair

Maintenance of the ZMZ 513 motor is quite simple. We can say that it is similar to 511. Maintenance is carried out every 12-15 thousand kilometers. This indicator includes changing the engine oil and filter element. It is also recommended to check the ignition and the condition of the air filter.

Do not forget that the air element is replaced every second maintenance.

The engine is not particularly demanding in the use of fuel and engine oil. So, for normal operation any more or less high-quality mineral lubricant is suitable. As practice shows, motorists usually pour oil such as M10 into the engine.

It perfectly performs all the necessary functions, and also, if replaced in a timely manner, protects the engine elements well. It is recommended to pay special attention to the air filter. It is best to take a quality product with a metal base.

A little more about the design

Today, an injector is very often installed. ZMZ-513 with such a fuel supply system becomes more economical and stable. If the carburetor at a high temperature outside led to boiling of gasoline and overheating of the fuel system, then injectors do not have such a problem.

Since initially the resource was not so great, although for those times it was more than sufficient, many motorists rebuilt the engine. To do this, they took spare parts from the same ZMZ, only of a later modification. In terms of costs, such interventions can be assessed as a full-fledged overhaul, but the service life of the internal combustion engine increased by approximately 35%. Therefore, the money spent was returned quite quickly.

Correct and careful operation

Any engine needs periodic scheduled and major repairs. But if scheduled technical work must be performed every 20 thousand kilometers, depending on the power unit, then when the time for capital comes depends only on the driver. To maximize the life of the motor, it is recommended:

• change the oil in the system on time and monitor its level;
• periodically inspect the cooling system to prevent overheating;
• try to operate the 513 in a gentle manner.

All this will help somewhat extend the life of the motor. Of course, design flaws and possible manufacturing defects should not be ruled out. All this occurs, but most often the 13th fails precisely because of the lack of proper maintenance. Replacing the fuel, oil and air filter is actually not that difficult. But at the same time, such a simple action will increase dynamics and reduce fuel consumption.