Zmz 514 DIY repair

Details: ZMZ 514 DIY repair from a real master for the site my.housecope.com.

The diesel engine ZMZ 514 is produced at the Zavolzhsky Motor Plant, and is the only diesel engine representative of the entire line of engines of this type. Initially, the power unit was intended for trucks produced by the GAZ group of companies, but the bulk of the engines are bought by UAZ for installation on their cars.

Unlike gasoline counterparts, the diesel has received improved technical characteristics, which has become popular with the people. Thus, the power unit of the Zavolzhsky plant received one of the best fuel systems produced by BOSCH. A poly V-belt with an auto-tensioner was also installed to drive the injection pump, pump and generator into operation. An upgraded Common Rail fuel supply system was installed on the engine.

Consider a ZMZ 514 diesel and its technical characteristics:

The main part is installed on vehicles manufactured by the Ulyanovsk Automobile Plant, namely: UAZ Patriot (Diesel), Hunter, Pickup and Cargo.

The maintenance of the 514th internal combustion engine is carried out in a typical way, as for all domestic diesel vehicles. The service interval is 12,000 km, but most experts and motorists agree that in order to preserve and increase the resource, it is necessary to reduce this figure to 10,000 km.

During maintenance, consumables and oil are changed. The first point includes filters for coarse and fine oil purification, as well as fuel filters. Depending on the operating conditions, it is also recommended to check the air filter, which can be clogged after 15-20 km.

Video (click to play).

When carrying out maintenance, especially if it is done by hand, it is worth paying special attention to the condition of the injectors, glow plugs, as well as the condition of the high pressure fuel pump.

Untimely repair of the latter can lead to more serious damage to the plunger pair, which will entail additional investment.

Repairing a 514 series diesel engine is quite difficult at home. So, you can carry out minor repairs, but larger breakdowns are recommended to be repaired in a car service.

At home, you can repair the fuel pump, replace the glow plugs, change the valve cover gasket.

The main problem that motorists often face is the tripping of a diesel power unit. In this case, often the problem can be hidden in clogged nozzles or a malfunction of the high pressure fuel pump. Both parts require special equipment for repair, and therefore it is worth contacting a car service to fix the malfunction.

Cleaning and diagnostics of injectors is carried out on a special stand, which will allow you to clearly identify the faulty element. As for the injection pump, it also requires special knowledge and skills that not every motorist possesses.

Often, the elements of the cooling system fail, which are easy enough to change at home. These include the thermostat and water pump. So, due to low-quality spare parts, the thermostat can often wedge, which leads to overheating of the engine or constant operation of the electric fan. As for the water pump, it breaks down - when the formation is formed on bearings.

The second option is the formation of a leak from under the shaft, which is easy to determine on your own. Changing the element is quite simple, you need to dismantle the drive belt and unscrew a few fastening bolts.

The diesel engine ZMZ 514 has gained widespread popularity on vehicles produced by the Ulyanovsk Automobile Plant. The simplicity of the design, which is typical for all motors produced by the Zavolzhsky Motor Plant, makes it quite simple and easy to repair the motor yourself. The power unit is serviced every 12,000 km.

The main task of this publication is to provide the system "developer-manufacturer-user of all forms" with technical information, which allows everyone interested to get comprehensive answers to all questions related to ensuring the performance of the ZMZ-514.10 diesel engine and its modifications at different stages of operation.
At present, intensive design and technological work is underway to develop modifications of diesel engines of JSC Zavolzhsky Motor Plant, to raise the requirements of environmental standards. Since January 1, 2008, the plant has been producing engines of only ecological class 3 *.
For updated information, we recommend that you visit the website.
Official edition.
Corresponds to the design and technological documentation as of August 12, 2008.
For the latest information, please contact the dealers of JSC "ZMZ".

The book briefly introduces the design features of the ZMZ-51432 diesel engine installed on UAZ vehicles of environmental class 4 (Euro 4). The book contains the main technical data and characteristics of the engine and its units, recommendations for their maintenance and repair are given.
Devices used in repairing and checking the performance of individual units are described. Possible engine malfunctions, their causes and remedies are indicated.
Due to the constant improvement of the design of UAZ vehicles and ZMZ diesel engines, individual parts and assemblies of your engine may differ from those given in this book.
The book is intended for specialists of service stations, auto repair and motor transport enterprises, and can also be useful to owners of UAZ vehicles, students and people studying the design of diesel engines.
The book on the arrangement, operation, maintenance and repair of diesel engines of the ZMZ-51432 model for UAZ vehicles of ecological class 4 has been prepared for publication by the Office of the Chief Designer of the Technical Department of ZMZ OJSC.

Installation and repair of the ZMZ-514 diesel engine, repair of the ZMZ-514 timing chain, replacement of the intermediate shaft bushing in ZMZ-514 in UAZ Hunter 31519

And once again we got a surprise from the ZMZ-514 diesel engine. Once again he showed us that the best is the enemy of the good.
It all started with chain tensioners. We read on the internet that mechanical chain tensioners are better than hydraulic chain tensioners. Like with them, there will be more oil pressure (there is a problem with pressure on this miracle of Russian diesel engineering) and everything will be all right with the chain tension. We changed the standard hydromechanical tensioners for purely mechanical ones from the “Russian Bogatyr”. And… we got a surprise - a chain jump. They began to understand and here it is the reason. The top tensioner made a long life:

Read also:  Repair of a fuel pump vaz 21093 do-it-yourself injector

Hana mechanical tensioner

But the surprises did not end there. On closer examination of the timing mechanism, a bump of the scrubber sprockets was found. After another disassembly of the front of the engine, it turned out that the sprocket bolts had again been cut off.
And again, these are not all surprises. The shaft dangled decently. After removal, it turned out that the front bushing of the scrubber was "over":

In general, we arrived. Then we ourselves could not do anything. Special equipment required. We found a company nearby that is professionally engaged in boring crankshafts and other shafts. We are familiar with the problem of prompts in our engines firsthand. They said: bring the block - we'll do it.
Block! The same engine must be removed and disassembled. And we decided to try it ourselves.
We bought a garage crane for 2 tons and started. Here they attached a crane to the UAZ:

It turned out that it was not that difficult to uncouple the engine. The gearbox does not need to be removed. As expected, the boom lift was enough, even the stock remained:

Lowered the diesel engine onto the pallet:

Then they moved the boom to a shorter distance, hung it back on the crane and rolled it right on the crane into the gazebo. These photos simply do not exist. They rested and rolled the entire structure. Then, in the gazebo, the diesel engine was washed of dirt, disassembled and immersed in the cylinder block in the second UAZ - Patrick. And the tap packaging came in handy :).
In this photo, you can already see the disassembled stand for assembling the engine:

The assembly stand is a simple device that will help us put the diesel back together.
In the meantime, this block will go to the specialists for repressing the bushings and adjusting the blades.

And we are rewarded with invaluable experience in disassembling the engine

In short, it gouged the front intermediate shaft bushing. Completely gouged:

Slotted front flush hub.

For repairs, a kit was purchased in the form of a new blast shaft and a set of blast shaft bushings. Everything cost about 2'000 rubles in the Planet of Zhelezyaka. Then the diesel was removed from the car using a garage crane (more details in the 13th part of the link above), disassembled to a “clean block of cylinders” and the block was taken to the Mechanics company, which is engaged in boring and adjusting the shafts. For 1'140 rubles, they repressed the bushings, unrolled and sanded the rim shaft to fit. This is what the new bushing looks like:

New front flange hub.

The prom shaft sits tightly without backlash.

Then it was the turn to show themselves to the engine assembly stand.
We bought a stand last weekend. And, in general, they did not regret it. The stand cost us 2'250 rubles, but the convenience of working with it covers all these costs. We don't have a garage, so we do everything either right on the street or in a gazebo.
Here is a cylinder block with a crankshaft already installed on the stand:

And then, with a “slight movement of the hand,” we turn the block over and insert the pistons with connecting rods:

In the background, an engine extraction crane is visible. When assembled, it takes up almost no space.

Sometimes, during heated discussions between the pilot and the navigator, during the process of assembling a diesel engine, the laptop turned into a tablet and approached the assembly object 🙂:

Generally? the assembly process with such preparation turned out to be not very complicated and pleasant.

Yes! Important. The tools must have a torque wrench. We did not have. I had to buy. The price of the issue is 1'150 rubles. At the same time, we decided to update some of the timing parts. We put new sprockets on the ramshaft, chains and hydraulic tensioners. During the day, taking into account the trip to the forest for raspberries, they assembled the engine and set the alignment of the crankshaft and camshaft marks. Here on this Saturday and stopped:

In the manual for assembling ZMZ-514, we found a new term for us - “to pick up”. Pick up the connecting rods, pick up the head, etc. So we decided, before putting the great diesel ZMZ-514 on Zyobrik, to “pick up” it and try to start it.

All that could be picked up at the stand (see the previous 14th entry in the BZ). But you can't put a flywheel on the stand, for example. This means that you cannot set the high-pressure fuel pump for sure.
In general, we began to sculpt a stand for winding up from scrap materials. We took as a basis a sheet of 18-mm plywood that served us well and trimmed various wooden products:

We sculpt a stand for starting the engine

Then they rolled the assembly stand under the crane:

We hung the engine on a crane and removed the load on the assembly stand:

They unhooked the assembly stand, rolled it out of the tap, set up a self-made stand for starting up and lowered the diesel on it:

They put it down on the booth for the start-up.

Then they screwed the engine mounts to the stand, assembled the engine to the minimum condition necessary for starting up, attached the power system from the old expansion tank and pumped the injection pump with injectors:

We connected the starter and the injection pump valve with hastily made wires to the battery and got ready for the moment of truth - the launch: