Mazda

When to change the timing chain on a UAZ Patriot. We change the timing belt on a UAZ Patriot Iveco (diesel). Preparing to replace the timing belt

The UAZ Patriot 409 engine from the Zavolzhsky Motor Plant has recently been brought to the Euro-4 environmental standard. In fact, this is an injection 406 engine, which was installed on the Volga and GAZelle. The actual design of the power units is very similar, in addition, the problems of the 406 engine were inherited by the ZMZ 409 engine. Below we offer a description and technical characteristics of the UAZ Patriot 409 engine.

The petrol, in-line, 4-cylinder, 16-valve unit has an aluminum cylinder block (with cast iron liners inside) and an aluminum cylinder head. The cylinder head has two camshafts that rotate via a timing chain drive. The valve mechanism has hydraulic compensators that free you from manually adjusting the thermal clearance of 16 valves.

The gas distribution mechanism of the ZMZ 409 UAZ Patriot engine

The camshafts are cast from cast iron. To achieve high wear resistance of the working surface, the cams were whitened. The shafts rotate in bearings formed by the cylinder head and removable aluminum covers. These covers are machined together with the cylinder head and are therefore not interchangeable. The camshaft drive is a two-stage chain drive. Includes: star 1 crankshaft driven 5 and presenter 6 intermediate shaft sprockets, driven sprockets 12 And 14 camshafts, two chains (72 and 92 links) 4 And 9 , hydraulic tensioners with reinforced spring 2 And 8 , tensioner arms 3 And 7 and chain guides 13 , 16 And 17 . The chain tension of each stage is carried out by hydraulic tensioners located: one on the front cover of the cylinder block (chain cover), the other on the cylinder head.

➤ 1 – crankshaft sprocket ➤ 2 – lower hydraulic tensioner ➤ 3 – lower chain tensioner lever ➤ 4 – lower chain ➤ 5 – driven intermediate shaft sprocket ➤ 6 – driven intermediate shaft sprocket ➤ 7 – upper chain tensioner lever ➤ 8 – hydraulic tensioner upper ➤ 9 – upper chain ➤ 10 – installation mark on the sprocket ➤ 11 – alignment pins ➤ 12 – intake camshaft sprocket ➤ 13 – upper chain guide ➤ 14 – exhaust camshaft sprocket ➤ 15 – upper plane of the cylinder head ➤ 16 – middle chain guide ➤ 17 – lower chain guide ➤ M1 and M2 – installation marks on the block Perhaps it is the complex mechanism of the timing device 409 of the UAZ Patriot engine that causes a lot of trouble when operating the engine. Lack of oil pressure quickly damages hydraulic compensators; it is necessary to carefully monitor the oil level in the engine. And frequent breakdowns of hydraulic chain tensioners cause an unpleasant sound. The problem is solved by installing imported hydraulic tensioners and regularly changing high-quality oil. It is worth noting that the valves are interchangeable with similar valves of the VAZ-2108 engine. Below are the characteristics of the UAZ Patriot gasoline engine.

Engine UAZ Patriot 2.7 ZMZ 409 (128 hp) characteristics, fuel consumption

➤ Displacement – 2693 cm3 ➤ Number of cylinders – 4 ➤ Number of valves – 16 ➤ Cylinder diameter – 95.5 mm ➤ Piston stroke – 94 mm ➤ Power hp/kW – 128/94.1 at 4600 rpm ➤ Torque – 209.7 Nm at 2500 rpm ➤ Compression ratio – 9 ➤ Timing type/timing drive – DOHC/chain ➤ Fuel brand – AI 92 gasoline ➤ Ecological class – Euro-4 ➤ Maximum speed – 150 km/h ➤ Acceleration up to 100 km/h – n/a ➤ Fuel consumption in the city – n/a ➤ Fuel consumption in the combined cycle – n/a ➤ Fuel consumption on the highway – 11.5 liters This engine is very voracious, this is perhaps the main problem of the Patriot with this power unit at the moment . A rather outdated design that will not please you with its reliability. However, the price of the new UAZ Patriot makes us turn a blind eye to such disadvantages.

Replacing UAZ Patriot timing chains (instructions, photos) UAZ Patriot (3163-010, 3163-012, 3163-020, 3163-022, 3163-032)

The gas distribution mechanism on the UAZ Patriot car engine performs the function of synchronizing the crankshaft and camshaft, and also sets cycles for opening and closing valves. The efficiency of the engine, its trouble-free and reliable operation depend on its operation. That is why the operation of the timing system of the UAZ Patriot engine is very responsible. So, to increase the reliability of the timing mechanism, a chain drive is used, but it can also stretch or even break over time. As a result, individual parts and the timing chain itself must be replaced approximately every 80,000 km. Here we cannot say about the exact mileage, since it will depend on the operating conditions of the engine. If the engine is worn out, then replacing the chain may be required earlier. Chain wear will be manifested in its “clunking” - a high-frequency sound like from valves. In this article we will provide information on replacing chains and gears of the gas distribution mechanism. It is noteworthy that the timing mechanism of the UAZ Patriot uses 2 chains, conventionally lower and upper. Such a timing mechanism can be considered difficult to maintain, so replacing chains will require increased qualifications from the mechanic who will carry out the work.

The process of replacing timing chains ZMZ 409 Euro 3

Before you start working on the engine, you need to remove the radiator and drive belts of the power steering pump of the generator and pump. Loosen the clamp of the supply hose to the cooling system pump and remove the hose from the fitting. Remove the cylinder head cover. Remove the four bolts and remove the front cylinder head cover assembly with the fan drive clutch and fan (the viscous clutch and fan have been removed for clarity). Remove the water pump Remove the crankshaft speed sensor (synchronization sensor) Remove the crankshaft pulley (see “Replacing the UAZ Patriot crankshaft oil seals”). Remove the oil sump (see “Replacing the UAZ Patroit engine crankcase”). Remove the two bolts and remove the upper chain hydraulic tensioner cover with the gasket. Remove the cover carefully, as it is affected by the hydraulic tensioner spring. Then remove the hydraulic tensioner. Also remove the lower chain hydraulic tensioner. Remove the 7 bolts and chain cover. Remove the cover carefully so as not to damage the front crankshaft oil seal installed in it, the cover gaskets and the cylinder head gasket. Remove 1 bolt of the upper tensioner and remove the tensioner arm along with the sprocket. Also remove the lower tensioner arm. Also with an asterisk. Unscrew the 2 bolts and remove the plastic chain guide. Remove the gears from the camshafts by removing the bolts securing the gears to the camshaft flanges. Here you will need a puller. Unscrew the bolts 2 and lift up the chain guide 1. Bend the ends of the locking plate 6 and turn out the bolt 5, to do this, hold the intermediate shaft from turning by inserting a screwdriver into the hole of gear 3. Remove gear 4 by inserting a screwdriver between it and gear 3 and resting the screwdriver as a lever against gear 3. Remove gear 4 from the top chain and remove the chain by pulling it up. Remove gear 3 from the intermediate shaft and remove it from the lower chain. Remove the lower chain from the crankshaft gear.

If it is necessary to remove gear 2 from the crankshaft, first remove bushing 1 and the rubber O-ring between the bushing and gear. Then compress gear 2. The gears are removed using a puller.

After removal, wash the chains and gears in gasoline, wipe and dry them. Inspect the chains. If the chain bushings are cracked, chipped, or show significant wear, replace the chains. Replace gears whose teeth are chipped or chipped. Replace damaged chain guides. The tensioner sprockets must rotate freely on the axles. If the sprocket teeth are chipped or chipped, replace the tensioners.

Assembling the timing mechanism and installing timing chains of the UAZ Patriot (recommended tightening torques and tension)

If you removed the gear from the crankshaft, press it onto the crankshaft, install the O-ring and bushing. Rotate the crankshaft so that mark 1 on the crankshaft gear aligns with mark 2 on the cylinder block. In this case, the piston of the 1st cylinder will take the TDC position. Install chain guide 4 without tightening bolts 3 securing the guide. Place chain 5 on the crankshaft gear, having previously lubricated it with engine oil.

Place the chain on driven gear 1 and install the gear on the countershaft 2 so that the pinion pin fits into the countershaft hole. In this case, mark 4 on the gear must coincide with mark 5 on the cylinder block, and the chain branch passing through damper 3 must be tensioned.

Install the countershaft drive gear so that its locating pin fits into the hole in the driven gear. Screw in the two bolts securing the intermediate shaft gears, placing a locking plate under them. Tighten the bolts to a torque of 22–25 N/m (2.2–2.5 kgf/m) and secure them by bending the edges of the locking plate on the edge of the bolt heads. By pressing the tensioner lever, tension the chain and check the alignment of the marks on the gears and the cylinder block.

Tighten the chain guide mounting bolts.

Lubricate the upper chain with engine oil and then slide it onto the countershaft drive gear through the hole in the cylinder head. Place the chain on gear 2 and, turning the exhaust camshaft slightly clockwise, install gear 2 with the chain on it. The camshaft pin 8 should fit into the gear hole. Screw in bolt 1. Turn the camshaft using a wrench using the square on the camshaft. Then, slightly turn the camshaft counterclockwise to tighten the chain. The intermediate and crankshafts should not turn. Mark A should coincide with the top surface of the cylinder head. Remove bolt 6 and remove gear 4 from the intake camshaft. Place the chain on gear 4 and install gear 4 with the chain on the camshaft by turning the camshaft slightly clockwise. The camshaft pin 5 should fit into the gear hole. Turn the camshaft slightly counterclockwise to tighten the chain. Mark A on gear 4 should align with the top surface of the cylinder head. The remaining shafts should not rotate. Screw in bolt 6. Tighten bolts 1 and 6 to a torque of 46–74 N/m (4.6–7.4 kgf/m), holding the camshafts from turning with a key using the squares. Install damper 3 by pushing it into the hole in the cylinder head. Install damper 7. Reinstall the chain cover and water pump. Apply a thin layer of sealant to the sealing surfaces of the cylinder block and cylinder head sealing surfaces. Reinstall the cover carefully so as not to damage the seal. Install the hydraulic tensioners of the upper and lower chains, see “Assembly (“charging”) and installation of hydraulic chain tensioners”. Install the crankshaft pulley. Screw in the crankshaft pulley mounting bolt, then, engaging fifth gear and braking the car with the parking brake, tighten the bolt to a torque of 104–128 N/m (10.4–12.8 kgf/m), holding the crankshaft from turning. When the ratchet is tightened, the pulley is pressed onto the crankshaft. Turn the crankshaft two turns using the ratchet and set the piston of the 1st cylinder to the TDC position (see operation 3). Check that the marks match. Install the front cylinder head cover, first apply a layer of Hermesil sealant to the surface of the cover adjacent to the cylinder head. Tighten the cover fastening bolts to a torque of 12–18 N/m (1.2–1.8 kgf/m). Install the cylinder head cover. Tighten the cover mounting bolts to a torque of 6.0–12 N/m (0.6–1.2 kgf/m). Connect the hose and crankcase ventilation tube to the fittings on the valve cover, and the wires to the ignition coils. Place the ends of the high-voltage wires on the spark plugs. Install the previously removed belts and radiator of the cooling system.

In this article we will provide information on replacing chains and gears of the gas distribution mechanism. It is noteworthy that the timing mechanism of the UAZ Patriot uses 2 chains, conventionally lower and upper. Such a timing mechanism can be considered difficult to maintain, so replacing chains will require increased qualifications from the mechanic who will carry out the work.

The photo shows the timing mechanism of the UAZ Patriot and the catalog parts numbers of the mechanism

The process of replacing timing chains (lower, upper) on a UAZ Patriot (instructions, photos)

Before you start working on the engine, you need to remove the radiator (“Removing the UAZ Patriot radiator”)

and power steering pump drive belts (“UAZ Patriot Power Steering Belt”),

Loosen the clamp on the supply hose to the cooling system pump and remove the hose from the fitting.

Remove the cylinder head cover. Remove the four bolts and remove the front cylinder head cover assembly with the fan drive clutch and fan (the viscous clutch and fan have been removed for clarity).

Remove the crankshaft speed sensor (synchronization sensor) (see “UAZ Patriot crankshaft sensors”).

Remove the crankshaft pulley (see “Replacing the UAZ Patriot crankshaft oil seals”). Remove the oil sump (see “Replacing the UAZ Patroit engine crankcase”).

Remove the two bolts and remove the upper chain hydraulic tensioner cover with the gasket. Remove the cover carefully, as it is affected by the hydraulic tensioner spring. Then remove the hydraulic tensioner (see “Removing and disassembling hydraulic tensioners for UAZ Patriot timing chains”).

Also remove the lower chain hydraulic tensioner.

Remove the 7 bolts and chain cover. Remove the cover carefully so as not to damage the front crankshaft oil seal installed in it, the cover gaskets and the cylinder head gasket.
Remove 1 bolt of the upper tensioner and remove the tensioner arm along with the sprocket.
Also remove the lower tensioner arm. Also with an asterisk.
Unscrew the 2 bolts and remove the plastic chain guide.

Remove the gears from the camshafts by unscrewing the bolts securing the gears to the camshaft flanges (see “Removing, troubleshooting and installing camshafts”). Here you will need a puller.

Unscrew the bolts 2 and lift up the chain guide 1. Bend the ends of the locking plate 6 and turn out the bolt 5, to do this, hold the intermediate shaft from turning by inserting a screwdriver into the hole of gear 3. Remove gear 4 by inserting a screwdriver between it and gear 3 and resting the screwdriver as a lever against gear 3. Remove gear 4 from the top chain and remove the chain by pulling it up. Remove gear 3 from the intermediate shaft and remove it from the lower chain. Remove the lower chain from the crankshaft gear.

If it is necessary to remove gear 2 from the crankshaft, first remove bushing 1 and the rubber O-ring between the bushing and gear. Then compress gear 2. The gears are removed using a puller.

After removal, wash the chains and gears in gasoline, wipe and dry them.
Inspect the chains. If the chain bushings are cracked, chipped, or show significant wear, replace the chains.
Replace gears whose teeth are chipped or chipped.
Replace damaged chain guides.
The tensioner sprockets must rotate freely on the axles. If the sprocket teeth are chipped or chipped, replace the tensioners.

Assembling the timing mechanism and installing timing chains of the UAZ Patriot (recommended tightening torques and tension)

If you removed the gear from the crankshaft, press it onto the crankshaft, install the O-ring and bushing.
Rotate the crankshaft so that mark 1 on the crankshaft gear aligns with mark 2 on the cylinder block. In this case, the piston of the 1st cylinder will take the TDC position. Install chain guide 4 without tightening bolts 3 securing the guide. Place chain 5 on the crankshaft gear, having previously lubricated it with engine oil.

Install the countershaft drive gear so that its locating pin fits into the hole in the driven gear.
Screw in the two bolts securing the intermediate shaft gears, placing a locking plate under them. Tighten the bolts to a torque of 22–25 N m (2.2–2.5 kgf m) and secure them by bending the edges of the locking plate on the edge of the bolt heads.
By pressing the tensioner lever, tension the chain and check the alignment of the marks on the gears and the cylinder block.

Tighten the chain guide mounting bolts.

Lubricate the upper chain with engine oil and then slide it onto the countershaft drive gear through the hole in the cylinder head.
Place the chain on gear 2 and, turning the exhaust camshaft slightly clockwise, install gear 2 with the chain on it. The camshaft pin 8 should fit into the gear hole. Screw in bolt 1. Turn the camshaft using a wrench using the square on the camshaft. Then, slightly turn the camshaft counterclockwise to tighten the chain. The intermediate and crankshafts should not turn. Mark A should coincide with the top surface of the cylinder head. Remove bolt 6 and remove gear 4 from the intake camshaft. Place the chain on gear 4 and install gear 4 with the chain on the camshaft by turning the camshaft slightly clockwise. The camshaft pin 5 should fit into the gear hole. Turn the camshaft slightly counterclockwise to tighten the chain. Mark A on gear 4 should align with the top surface of the cylinder head. The remaining shafts should not rotate. Screw in bolt 6. Tighten bolts 1 and 6 to a torque of 46–74 N m (4.6–7.4 kgf m), holding the camshafts from turning with a key using the squares. Install damper 3 by pushing it into the hole in the cylinder head. Install damper 7.
Reinstall the chain cover and water pump. Apply a thin layer of sealant to the sealing surfaces of the cylinder block and cylinder head sealing surfaces. Reinstall the cover carefully so as not to damage the seal.
Install the hydraulic tensioners of the upper and lower chains, see “Assembly (“charging”) and installation of hydraulic chain tensioners”. Install the crankshaft pulley. Screw in the crankshaft pulley mounting bolt, then, engaging fifth gear and braking the car with the parking brake, tighten the bolt to a torque of 104–128 N m (10.4–12.8 kgf m), holding the crankshaft from turning. When the ratchet is tightened, the pulley is pressed onto the crankshaft.
Turn the crankshaft two turns using the ratchet and set the piston of the 1st cylinder to the TDC position (see operation 3). Check that the marks match.
Install the front cylinder head cover, first apply a layer of Hermesil sealant to the surface of the cover adjacent to the cylinder head. Tighten the cover mounting bolts to a torque of 12–18 N m (1.2–1.8 kgf m).
Install the cylinder head cover. Tighten the cover mounting bolts to a torque of 6.0–12 N m (0.6–1.2 kgf m). Connect the hose and crankcase ventilation tube to the fittings on the valve cover, and the wires to the ignition coils. Place the ends of the high-voltage wires on the spark plugs.

Install the previously removed belts and radiator of the cooling system.

You will need: a 6-point hex key, 12-point, 13-point, 14-point sockets, a small chisel, and a hammer.

1. Drain the cooling system (see “Replacing the coolant”).

2. Remove the radiator of the cooling system (see “Removing and installing the radiator”).

3. Remove the power steering pump drive belt and fan pulley (see “Replacing the power steering pump drive belt and cooling fan drive viscous clutch”).

4. Remove the generator and water pump drive belt (see “Replacing the generator and water pump drive belt”).

9. Remove the crankshaft speed sensor (synchronization sensor) (see “Engine management system sensors”).

10. Remove the crankshaft pulley (see “Replacing the crankshaft oil seals”).

11. Remove the oil sump (see “Replacing the oil sump seal”).

14. Remove the seven bolts and remove the chain cover. Remove the cover carefully so as not to damage the front crankshaft oil seal installed in it, the cover gaskets and the cylinder head gasket.

15. Remove the upper tensioner bolt and remove the tensioner lever with sprocket.

16. Similarly, remove the lower tensioner arm with the sprocket.

19. Unscrew the bolts 2 and lift up the chain guide 1. Bend the ends of the locking plate 6 and turn out the bolt 5, to do this, hold the intermediate shaft from turning by inserting a screwdriver into the hole of gear 3. Remove gear 4 by inserting a screwdriver between it and gear 3 and resting the screwdriver as a lever against gear 3. Remove gear 4 from the top chain and remove the chain by pulling it up. Remove gear 3 from the intermediate shaft and remove it from the lower chain. Remove the lower chain from the crankshaft gear.

20. If it is necessary to remove gear 2 from the crankshaft, first remove bushing 1 and the rubber sealing ring between the bushing and the gear. Then compress gear 2 using a puller.

21. After removal, wash the chains and gears in gasoline, wipe and dry them.

22. Inspect the chains. If the chain bushings are cracked, chipped, or show significant wear, replace the chains.

23. Replace gears whose teeth are chipped or chipped.

24. Replace damaged chain guides.

25. The tensioner sprockets must rotate freely on the axles. If the sprocket teeth are chipped or chipped, replace the tensioners.

26. If you removed the gear from the crankshaft, press it onto the crankshaft, install the O-ring and bushing.


27. Rotate the crankshaft so that mark 1 on the crankshaft gear aligns with mark 2 on the cylinder block. In this case, the piston of the 1st cylinder will take the TDC position. Install chain guide 4 without tightening bolts 3 securing the guide. Place chain 5 on the crankshaft gear, having previously lubricated it with engine oil.	28. Place the chain on driven gear 1 and install the gear on the countershaft 2 so that the gear locating pin fits into the hole in the countershaft. In this case, mark 4 on the gear must coincide with mark 5 on the cylinder block, and the chain branch passing through damper 3 must be tensioned.

29. Install the countershaft drive gear so that its locating pin fits into the hole in the driven gear.

30. Screw in the two bolts securing the intermediate shaft gears, placing a locking plate under them. Tighten the bolts to a torque of 22–25 N·m (2.2–2.5 kgf·m) and secure them by bending the edges of the locking plate on the edge of the bolt heads.

31. Press the tensioner lever, tighten the chain and check the alignment of the marks on the gears and the cylinder block.

32. Tighten the chain guide bolts.

33. Lubricate the upper chain with engine oil and then slide it onto the countershaft drive gear through the hole in the cylinder head.

34. Place the chain on gear 2 and, turning the exhaust camshaft slightly clockwise, install gear 2 with the chain on it. The camshaft pin 8 should fit into the gear hole. Screw in bolt 1. Turn the camshaft using a wrench using the square on the camshaft. Then, slightly turn the camshaft counterclockwise to tighten the chain. The intermediate and crankshafts should not turn. Mark A should coincide with the top surface of the cylinder head. Remove bolt 6 and remove gear 4 from the intake camshaft. Place the chain on gear 4 and install gear 4 with the chain on the camshaft by turning the camshaft slightly clockwise. The camshaft pin 5 should fit into the gear hole. Turn the camshaft slightly counterclockwise to tighten the chain. Mark A on gear 4 should align with the top surface of the cylinder head. The remaining shafts should not rotate. Screw in bolt 6. Tighten bolts 1 and 6 to a torque of 46–74 N·m (4.6–7.4 kgf·m), holding the camshafts from turning with a key using the squares. Install damper 3 by pushing it into the hole in the cylinder head. Install damper 7.

35. Install the chain cover and water pump. Apply a thin layer of Hermesil sealant or similar to the surfaces of the covers adjacent to the cylinder block and head. When installing the chain cover, be careful not to damage the crankshaft oil seal.

36. Install the hydraulic tensioners of the upper and lower chains, see “Assembly (“charging”) and installation of hydraulic chain tensioners”. Install the crankshaft pulley. Screw in the crankshaft pulley mounting bolt, then, engaging fifth gear and braking the car with the parking brake, tighten the bolt to a torque of 104–128 N·m (10.4–12.8 kgf·m), holding the crankshaft from turning. When the ratchet is tightened, the pulley is pressed onto the crankshaft.

37. Turn the crankshaft two turns using the ratchet and set the piston of the 1st cylinder to the TDC position (see operation 3). Check that the marks match.

38. Install the front cylinder head cover; first apply a layer of Hermesil sealant to the surface of the cover adjacent to the cylinder head. Tighten the cover mounting bolts to a torque of 12–18 N·m (1.2–1.8 kgf·m).

39. Install the cylinder head cover. Tighten the cover mounting bolts to a torque of 6.0–12 N·m (0.6–1.2 kgf·m). Connect the hose and crankcase ventilation tube to the fittings on the valve cover, and the wires to the ignition coils. Place the ends of the high-voltage wires on the spark plugs.

40. Install the previously removed attachments.