Do-it-yourself gazelle business 4216 engine repair

Gazelle until 2009. Disassembly and assembly of the UMZ-4216 engine - part 1

We disassemble the engine to assess the technical condition and replace the failed parts of the crank mechanism. Remove the engine from the car (see "Removing and installing the engine", p. 67). To securely fix the engine, we put wooden blocks of suitable dimensions under the brackets of the power unit supports, the oil pan, the clutch housing and disconnect the lifting chain from the eyebrows. Remove the cylinder head assembly with the receiver, intake pipe and exhaust manifold (see "Removing the cylinder head", p. 56).

Remove the generator and its lower mounting bracket (see "Removing the 3282M.3771 generator", p. 267). Remove the starter (see "Removing and checking the starter", p. 272).

Using the "24" wrench, unscrew the adapter assembly with a tap from the hole in the cylinder block.

Remove the crankshaft position sensor (see "Removing the crankshaft position sensor", p. 83) and the phase sensor (see "Removing the phase sensor", page 83).

Remove the crankshaft pulley (see "Replacing the front crankshaft oil seal", p. 59). We unscrew the oil filter (see "Changing the oil and oil filter", p. 44). Remove the coolant pump (see "Removing the coolant pump", page 112). Remove the fan drive belt tensioner (see "Removing the fan drive belt tensioner", p. 64). Remove the electromagnetic clutch for switching on the fan (see "Removing the electromagnetic clutch for switching on the fan", p. 110).

Further disassembly of the engine can be performed on a universal disassembly and assembly stand. To do this, it is necessary to remove the bracket of one of the power unit supports and attach the stand plate with bolts screwed into the threaded holes of the cylinder block, which are designed to fasten the power unit support bracket. If there is no stand, unscrew the cylinder head mounting studs from the cylinder block and install the block with the flat side on the workbench. Remove the brackets for the power unit supports (see "Replacing the power unit supports", p. 65). Using the “36” head, we unscrew the bolt securing the crankshaft pulley hub (we hold the shaft from turning with a mounting blade inserted between the teeth of the flywheel crown and the clutch housing).

Press the pulley hub off the toe of the crankshaft (see "Replacing the front crankshaft oil seal", p. 59).

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ChLeNoPoTaM 23 Dec 2016

Good day! something was wrong with my gazelle. compression disappeared, and after a while a knock and blue smoke and pipes appeared. an autopsy showed that the 4th cylinder had burned out and a crack in the second liner. took the block to the glorious city of Novocherkassk for pressurization and sleeve fitting. waiting for the results.

The question is the following, dear members of the forum. What do you recommend when assembling? I would like to assemble a high-quality and reliable engine!

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ZAN57 23 Dec 2016

Lord, what's wrong with the internal combustion engine? Did you drive on gas with late ignition? Overheated well? With pistons, you can still understand, but a crack in the liner? I have not encountered it yet.

It was good before - I replaced the insert liners and new pistons, rings. and order. by myself, in a couple of days.

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Valery (69) 24 Dec 2016

It was necessary to immediately take the repair pistons to them, so that the liners would fit on them.

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ChLeNoPoTaM 24 Dec 2016

mileage of the internal combustion engine 250,000. Only gasoline Lukoil 92. first gave it for pressure. then we'll see. just the first renovation 100.5. a used block from Nizhny Novgorod costs 12,000.sleeve 2100, replacing it with 1000. I don't even know, the problems started after I started pouring the suprotek. or just a coincidence

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Denisg 24 Dec 2016

Suprotek is an abrasive, no wonder.

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zoe76 24 Dec 2016

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ChLeNoPoTaM 25 Dec 2016

somewhere through 15 thousand began to podtraivat. but on troubleshooting, I realized that I have uniform wear on all pistons. on the other hand, there is more than one seizure on the main and connecting rod liners. the machine then worked at the company before me. and poured there, don't understand what, so I decided to wash the inside with all sorts of expensive washes. but inside it is clean and shining! and the question is still, there was a thread on candles in oil, sinned on the valve oil seals. changed but the problem did not go away. and the gap in the guides is normal

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ZAN57 25 Dec 2016

And often on 4216 liners crack?

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ChLeNoPoTaM 28 Dec 2016

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wanderer666 28 Dec 2016

Well it is necessary to ride on something. So that the sleeves are burst.

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ChLeNoPoTaM 29 Dec 2016

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Toyota007 29 Dec 2016

Looking at the piston is very similar to an overheating motor.

By the way, carbon deposits are not from gas but from gasoline, that's for sure. Gas is another carbon deposit.

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ZAN57 29 Dec 2016

Looking at the piston is very similar to an overheating motor.

By the way, carbon deposits are not from gas but from gasoline, that's for sure. Gas is another carbon deposit.

I agree, it doesn't look like gas. But suprotek evens out the surface due to the finely dispersed abrasive. But why did it crack? Most likely, simultaneously with overheating, a thermal shock. Did the cylinder head drive?

That you scared me. Previously, I changed the sleeve and that's it, I had 15 of them lying around in stock, 4 of them were new, the rest were used, but better than new ones.

in business, is it better to immediately change the sleeves or can you sharpen them? and do they change them in general? they are not pulled out there?

or can you sharpen it?
sharpen, they are poured

and generally they change?
cut out and inject with nitrogen a new

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ChLeNoPoTaM 29 Dec 2016

in the sleeve where the crack was, the compression was the highest. but crimping showed that another (which is intact) flows. In general, it costs 1000 rubles to change the sleeve. and the sleeve itself is 2100 and for some reason they do not give a guarantee. rarely does anyone do such work

Post has been editedChLeNoPoTaM on: 29 December 2016 - 19:15

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Stepnyak Dec 29, 2016

and why is there a hole in the oil fence?

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ChLeNoPoTaM 30 Dec 2016

For some reason I thought that the hole in the mesh was not a man-made creation

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rool Dec 30, 2016

For some reason I thought that the hole in the mesh was not a man-made creation

I saw this in two engines. In addition to sabotage, there is no thought. I didn't have this, but the first time I changed the oil, the filter was clogged with bits of sealant. The mesh is intact.

Good day! something was wrong with my gazelle. compression disappeared, and after a while a knock and blue smoke and pipes appeared. an autopsy showed that the 4th cylinder had burned out and a crack in the second liner. took the block to the glorious city of Novocherkassk for pressurization and sleeve fitting. waiting for the results.

The question is the following, dear members of the forum. What do you recommend when assembling? I would like to assemble a high-quality and reliable engine!

“High-quality” - naturally, a lot depends on the quality of spare parts. The same liners that are installed instead of the factory ones very often come across as if from a regular pipe. That is, wear in them occurs faster than in the factory ones .. (Although everyone knows that we have spare parts To assemble a reliable engine as you write, the first is the quality of the spare part. In general: pay special attention to the clearance between the piston and the cylinder, the thermal clearance in the rings, the wear of the connecting rod bushings, the weight of the pistons, the wear of the half rings on the CV even if everything is normal with the crankshaft, put new liners (the same size as they were), pay attention to the distribution gear, replace if necessary, check the camshaft bushings, of course, valve bushings, valves, valve seals in the cylinder head. oil intake, because it is broken in the photo. Pay attention to the wear of the ring on the flywheel. On these internal combustion engines, it often "eats". oil seals, gaskets, etc. Attached also during installation check for backlash, lubrication, etc., and Good luck with the assembly

The Ulyanovsk Motor Plant began to produce high-power engines since 1997, the carburetor UMP 4215 became the first internal combustion engine with a cylinder diameter of 100 mm, and in 1998 Ulyanovsk residents developed a new 110-horsepower injection engine. sec., corresponding to Euro-2 standards. Gasoline engines UMZ 4216 in pilot batches began to be produced in 2003, and soon they were put into series.

Model 4216 is installed on GAZ vehicles; this power unit is used in Gazelle commercial vehicles. In 2008, the Ulyanovsk engine was improved, and it began to comply with Euro 3 standards, and since 2012 it has been brought to the Euro 4 standard. In 2013, hydraulic expansion joints began to be used on this engine, since 2014, the Ulyanovsk plant began assembling EvoTech motors volume of 2.7 liters, which is installed on commercial vehicles Gazelle Business and Gazelle Next.

The prototype of the engine of the Ulyanovsk Motor Plant is the ZMZ-21 engine - it has essentially the same design:

• aluminum block of cylinders;
• upper arrangement of valves;
• gear drive of the gas distribution mechanism;
• aluminum rods;
• the lower location of the camshaft;
• two valves per cylinder.

Even the oil sump has a similar configuration - it is also steel, stamped, with recesses at the front and rear.

As in the ZMZ-21, on the Ulyanovsk engine, pistons with connecting rods are connected by means of "floating" piston pins - the pistons are seated on a "cold" one, copper (bronze) bushings are pressed into the upper connecting rod bushings.

On all UMP engines with a cylinder diameter of 92 mm, “wet” removable liners are installed in the cylinder block (BC). In a block with a piston diameter of 100 mm (models UMZ 4215, 4213 and 4216), the sleeves are pressed using special equipment, and during repairs it will not be possible to press them out, therefore, if the cylinders are significantly worn out, the BC needs to be replaced.

The 4216 engine consists of the following parts:

an aluminum cylinder block into which four cast iron liners are pressed;

The gas distribution mechanism (camshaft) is driven from the crankshaft through a pair of gears. The camshaft cams, through the tappets and rods, raise and lower the rocker arms, which in turn push the intake and exhaust valves. Due to the valves, the cylinders are filled with a fuel-air mixture, and the engine's operating cycle occurs.

On a Gazelle Business car, the UMZ 4216 engine is equipped with an electronic control system, which includes:

• control unit MIKAS;
• ignition module;
• high-voltage wires with lugs;
• sensors - throttle valve, to / shaft and p / shaft, absolute pressure, detonation;
• wiring;
• idle speed regulator;
• fuel injectors.

Motor 4216 - four-stroke, in-line four cylinders, 8-valve. The internal combustion engine is designed to run on AI-92 gasoline; it is allowed to use higher quality fuel, for example, AI-95 gasoline. The technical characteristics of the UMZ-42164 (Euro-4) modification engine are as follows:

• volume - 2890 cm³;
• diameter of standard pistons - 100 mm;
• compression ratio (compression in cylinders) - 9.2;
• piston stroke - 92 mm;
• power - 107 liters. With.;
• the engine cooling system is liquid (antifreeze or antifreeze is poured in).

The block and cylinder head are cast from an aluminum alloy. The engine of the first completeness weighs 177 kg, the power unit itself is included in the complete set of the motor, and attachments are also installed on it:

• starter;
• generator;
• intake manifold (receiver);
• ignition module with wires and lugs;
• drive belts;
• water pump;
• crankshaft pulley;
• basket and clutch disc;
• ECM sensors.

According to the factory standards, the fuel consumption of the Gazelle with the Ulyanovsk ICE is 10 l / 100 km on the highway outside the city, in mixed mode it is 11 l / 100 km. In practice, more gasoline is usually consumed, a lot depends:

• from the congestion of the car;
• speed limit;
• the period of operation (in winter, more fuel is consumed to warm up the fuel).

The engine of the UMZ 42164-80 modification is equipped with hydraulic compensators; this engine is used in the Sobol Business and Gazelle Business commercial cars. The 42164-80 model differs little from the standard 4216 motor - this engine is equipped with other, special stays, in the upper part of which the compensators themselves are attached.

Crankshaft 4216 consists of four connecting rod and five main connecting rod journals, has diameters:

• root necks - 64 mm;
• connecting rod journals - 58 mm.

All journals are equipped with two steel-babbit liners, the factory tolerance for the crankshaft dimensions is 0.013 mm. During the repair of the Ulyanovsk engine, the main and connecting rod journals are measured with a micrometer - if they are worn more than 0.05 mm, the shaft is subject to mandatory grinding. The diameter of the piston pins is 25 mm, the pins are installed in the bronze bushings of the connecting rods. Over time, both the fingers themselves and the bushings can wear out; in the event of backlash in the connection, the parts must be replaced.

The crankshaft in the cylinder block is mounted on supports with covers, which are tightened with bolts with a certain effort. Each cover has its own place - they should not be confused in places, moreover, picked up from another BC. Also, the covers must be locked to the lock - if they are installed incorrectly, the crankshaft may not scroll (it will be clamped), and even if the shaft does scroll, the engine will quickly fail.

The resource of the 4216 engine, declared by the manufacturer, is 250 thousand km, but often the engines fail ahead of schedule. Frequent ICE problems:

• leaking engine oil;
• increased oil burnout through the piston rings:
• knock of valves, which is sometimes difficult to eliminate;
• overheat;
• failure of various sensors.

Various breakdowns can occur prematurely for various reasons:

• the driver violates the operating conditions - the motor overheats due to overload;
• maintenance standards are not followed;
• the car is operated in difficult road conditions.

Unfortunately, defects are often found in UMP engines, but ZMZ motors are not insured against this either. If the 4216 engine troit (jerks), the cause of the malfunction may be both the engine itself and a breakdown in the ECM. To determine the cause of the defect, it is necessary to diagnose the internal combustion engine.

There are the most controversial reviews about the UMZ 4216 engine - some owners of Gazelles praise UAZ engines and believe that they:

Indeed, the UMZ 4216 engine is very simple, especially since it has significant similarities with the ZMZ-402 internal combustion engine. The design of the power unit is familiar to many drivers, and such an engine can be repaired almost in the field. Some difficulty for car owners is the electronic equipment of the motor - after all, the injector is somewhat more complicated than the carburetor device.

You can also hear extremely negative responses from the owners of Gazelles with UAZ engines:

• the engine is prone to overheating;
• sensors often fail, so the motor starts to triple and does not go;
• the engine consumes oil, it flows wherever possible.

Unfortunately, a lot of rejects come from the Ulyanovsk plant, and basically those drivers who get a defective internal combustion engine complain about the Ulyanovsk motor. There are several typical factory "blunders" that are quite common on the UMP 4216:

• the intake manifold cracks and begins to suck in air;
• the pump does not provide the required oil pressure;
• the electromagnetic cooling clutch refuses to work, and the motor begins to overheat.

Drivers of such unsuccessful "Gazelles" note that the engine often has to be "refined with a file." It was also noticed that if the motor is completely sorted out with our own hands, breakdowns in it occur much less often, the main thing is to assemble the engine using original parts of good quality.

During the operation of the Gazelle with the UMZ 4216 engine, various breakdowns occur, one of the most common problems is engine overheating. If the cooling system "airs", antifreeze (antifreeze) starts to be thrown out of the expansion tank. As a result of overheating, it often breaks through the block head gasket - it is generally easy to change the PHBTs, and often drivers make such repairs on their own.

But the problem in case of overheating is different - often from the high temperature on the pistons partitions burst, the piston rings "lie". To replace the pistons or rings, it is not necessary to remove the engine, it is enough just to throw off the block head and the oil pan.

UMP 4216 overhaul is necessary in cases when:

• worn or damaged cylinder liners;
• the crankshaft knocks (wears out);
• low oil pressure in the system, and replacing the oil pump does not give positive results.

Often the Ulyanovsk engine is overheated, and drivers take various measures to get rid of this unpleasant and dangerous phenomenon for the internal combustion engine. Many Gazelle owners install a three-row copper radiator instead of the standard aluminum one - copper cools antifreeze more efficiently. Another method to combat overheating is to install an electric cooling fan with a toggle switch located in the driver's cab. At the moment when the sensor arrow on the instrument panel begins to show the critical temperature of the coolant, the driver forcibly turns on the fan, and the temperature regime returns to normal.

In the case of purchasing a Gazelle with an unsuccessful engine, car owners seek to get rid of the power unit, replacing it with an internal combustion engine of another model. Many different options can be considered for replacement, but most often the owners of commercial cars install ZMZ-405 engines, this particular engine is chosen for a number of reasons:

• The Zavolzhsky engine is not capricious - it “digests” Russian fuel well, it rarely breaks down;
• relatively imported power units (Cummins, Toyota, Nissan) ZMZ-405 is inexpensive;
• when installing ZMZ, a minimum of alterations are required.

Recently, the Cummins turbodiesel has been regularly installed on Gazelle Business cars, but owners of cars with UMP-4216 almost never consider this engine as a replacement:

• Cummins isn't cheap;
• The American engine is very sensitive to the quality of fuel, and if the car is filled with bad diesel fuel, Cummins can quickly fail.

The advantage of the ZMZ-405 (or 406) also lies in the fact that a lot of used engines are sold in the secondary market in normal, working condition, and their price is several times lower than a new internal combustion engine. True, when buying a used unit, there are no serious guarantees - you have to take the seller's word for it. But even if the 405 requires minor repairs (replacement of chains or piston rings), it is still much cheaper to purchase it together with the repair than to purchase an expensive imported engine. Another disadvantage of the imported internal combustion engine is that if it was not serially installed on the Gazelle, it will have to be purchased together with the gearbox or be puzzled by the fit of the Gazel gearbox to the new engine.

A flexible system of discounts is provided for regular customers.

For work on overhaul and installed spare parts a guarantee is given - 6 months no mileage limitation.

In our work we use original spare parts of OJSC GAZ, a full range of spare parts are always available in stock.

The total cost of the overhaul of an engine is made up of the cost of labor and the cost of spare parts. The cost of work is fixed and does not change. The cost of spare parts depends on the condition of your engine directly, after opening, disassembling and troubleshooting the engine, a list of spare parts necessary for overhaul is compiled and the cost of parts is also calculated.

Structurally, the motor is descended from the ancestor of the family - the ZMZ 402 engine.The engine has a lower camshaft, the valves are driven by rods through the rocker arms.
In principle, the unit is quite reliable, repairs are mainly due to factory defects or errors in operation. Widely distributed on the Gazelle Business model.

Factory defects include the loss of the valve seat from the cylinder head, with subsequent damage to the piston and cylinder block. The plant knows about this defect and now the valve seats are additionally wedged in the block head.

Defects caused by improper operation: untimely oil change leads to coking of the oil channels and the oil receiver mesh, as a result, a drop in oil pressure and wear of the crankshaft journals.

Prolonged driving with thermal disturbances (overheating) leads to seizures on the piston skirt and on the cylinder liner.

We carry out all types of machining: grinding of the block head, boring, liner of cylinder blocks, grinding of crankshafts.

Our recommendations for the operation and extension of the service life of UMZ 4216 motors before overhaul:
- Daily oil level check.
- The use of quality engine oil - our recommendation - Mobil, Motul.
- Compliance with the service interval for mileage - 10.000 km.
- Operation of the motor with current gaskets, oil seals, hoses and connections of the cooling system is inadmissible.
- Temperature control, inadmissibility of overheating.
- Monitoring the coolant level.
- It is necessary to observe the operating modes of the engine in terms of revolutions, do not twist.
- Daily visual inspection of the engine compartment, checking the levels.

Subject to these simple recommendations, the resource of UMZ 4216 engines before overhaul on a / m Gazelle Business, Sable, Gazelle Next in terms of mileage is about 200,000-250,000 km.

If necessary, you can come to us for inspection - it's free.

The 4216 Euro 3 engine is designed for installation on Gazelle vehicles. But, many motorists were faced with the fact that triple formation occurred during the operation of the motor. What are the reasons for the effect and methods of solving independently.

Before proceeding directly to the consideration of the reasons why the engine is troit, as well as to the methods of solution, we will consider the main technical characteristics of the power unit. As practice has shown, the power unit has sufficiently high technical characteristics, and therefore it is loved by many motorists.

A simple device and reliability made the engine common among Gazelle car owners. Consider the main technical characteristics of the power unit:

This type of engine was used on the Gazelle Business and Next vehicles.

Any engine tends to break down. So, UMP 4216 E-3 is also prone to malfunctions. In this article, we will consider why the power unit is troit, as well as methods for diagnosing and treating this malfunction. Perhaps most motorists have encountered this problem and know how to fix it.

So, let's consider what elements of a car engine can lead to the fact that the power unit begins to triple:

• Poor quality fuel.
• Defective sensors.
• Malfunction in the fuel system.
• The air is to blame.
• Ignition problem.
• The valve and the piston are a disaster.
• ECU.

When the root causes have been identified, you can proceed to troubleshoot the problem. Before you start, it is worth noting that not all motorists are able to figure out and fix the problem. So, you need to have certain knowledge in the design of cars, as well as be able to correctly diagnose.

Therefore, it is strongly recommended that if a car enthusiast is not confident in his abilities, contact a specialized car service, where professional workers can quickly and efficiently eliminate the malfunction. Well, those who decided to try it themselves should be patient.

Troit the power unit, most likely due to the flooded low-quality fuel, which clogged the entire system.So, to solve the problem, it is necessary to clean the entire fuel line and the fuel tank. Also, it is recommended to check the injectors and the fuel filter. After repairs, fill only with high-quality fuel, at proven fuel stations.

Another common problem is the malfunction of the engine sensors. So, the output of one or more measuring elements can lead to the fact that the motor starts to triple, which is very unpleasant. In this case, an increase in consumption will be observed. Therefore, to diagnose meters, it is worth stocking up on a multimeter, with the help of which the performance of the elements will be determined.

So, let's consider which sensors will affect the engine operation:

• The first meter worth diagnosing is the temperature sensor. It is this element that most often fails. So, if it was determined that the meter is out of order, it must be replaced.
• In addition to the temperature sensor, it is worth paying special attention to the performance of the idle sensor and the throttle position sensor. These meters directly affect the operation of the engine, and the production of the air-fuel mixture.
• The following elements are not so important, but they also need to be checked: oxygen sensor, DMVR, crankshaft and valve timing sensor.

A malfunction of the fuel system directly affects the air / fuel mixture, and therefore this system should be checked carefully. First, clogged injectors can affect fuel delivery. Cleaning of these elements is carried out at a special stand, but many motorists do it on their own and are not always successful. If necessary, the nozzle should be replaced.

Secondly, it is worth checking the operation of the fuel pump, which may not pump fuel due to a clogged filter mesh. Also, it is recommended to change the fuel filter. After that, you can proceed directly to the diagnosis of the remaining elements.

Like fuel, air plays an important role in the formation of an air-fuel mixture. Therefore, the diagnostics of the air supply should be carried out on a par with the fuel system. Particular attention should be paid to the throttle valve. The clogging of this element can disrupt the balance of the air-fuel system, which leads to triple formation. The element is cleaned using a special liquid or carburetor cleaning spray.

Also, don't forget about the air filter. A clogged element does not allow enough air to enter the combustion chambers, which causes triple formation. An element change must be carried out every second maintenance, but not later than 30,000 km of run.

Another system that will affect the operation of the power unit is the ignition system. In the event of a malfunction of one or more spark plugs, the engine does not receive a spark into the combustion chamber, and accordingly, not all cylinders work. Diagnostics of candles is quite simple.

They are inspected for damage, oiliness and checked on a special stand or "old-fashioned" method, which is known to almost all motorists. An important role is played by high-voltage wires, which are also worth checking for performance and resistance.

The worst case, in which the engine is troit, is a malfunction of the mechanical parts. So, burnout of valves and pistons will lead to unstable engine operation. Also, this is the first sign that the power unit needs a major overhaul. For diagnostics, it is necessary to dismantle the cylinder head, which will show the state of the piston group and valves.

Cleaning the exhaust valves and pistons will not be enough to rectify the problem. In this case, it becomes clear that the engine elements have exhausted their resource and it is worth replacing them. This operation is recommended to be performed in a car service.

The last place to look for faults is the electronic engine control unit. It is here that errors could accumulate that prevent the motor from working stably.Many professional diagnosticians start troubleshooting right here, because you can immediately see which of the sensors is out of order, and maybe the problem lies in it.

To carry out self-diagnosis, you will need several items - an OBD II cable, a laptop and the corresponding software.

But, many auto repairmen do not recommend carrying out the operation on their own, since irreparable damage to the electronic control unit and software can be caused, after which you will have to re-flash the ECU.

As you can see, the UMZ 4216 E-3 engine is troit for various reasons. You can fix this malfunction with your own hands, without contacting a car service. So, the motorist must know the design and principle of operation of the vehicle, as well as be able to diagnose the elements that may be the cause of the problem.