The ZMZ-40524.10 engine is a modification of the ZMZ-40522.10 engine in order to meet Euro3 toxicity standards and increase its reliability and service life
ZMZ-40524 engines. 10 are designed for installation on trucks and buses of the GAZelle family with a gross weight of up to 3500 kg and on cars of the Sobol family with a gross weight of up to 2980 kg, manufactured by GAZ OJSC.
Motors are manufactured in U2 climatic version, designed for operation in moderate climates at ambient temperatures from minus 45°C to plus 40°C and relative air humidity up to 100% at a temperature of plus 25°C.
Cross section of engine mod. 40524: 1 - oil sump; 2 - oil pump receiver; 3 - oil pump; 4 - oil pump drive; 5 - intermediate shaft gear; 6 - cylinder block; 7 - inlet pipe; 8 - receiver; 9 - intake camshaft; 10 - inlet valve; 11 - valve cover; 12 - exhaust camshaft; 13 - oil level indicator; 14 - hydraulic valve tappet; 15 - outer spring of the valve; 16 - valve guide sleeve; 17 - exhaust valve; 18 - cylinder head; 19 - exhaust manifold; 20 - piston; 21 - piston pin; 22 - connecting rod; 23 - crankshaft; 24 - connecting rod cover; 25 - main bearing cap; 26 - drain plug; 27 - pusher body; 28 - guide sleeve; 29 - compensator body; 30 - retaining ring; 31 - compensator piston; 32 - ball valve; 33 - ball valve spring; 34 - body of the ball valve; 35 - expanding spring
Cross section of the ZMZ-40524 engine
The left side of the ZMZ-40524 engine: 1 - control system coolant temperature sensor; 2 - coolant overheat indicator sensor; 3 - emergency oil pressure alarm sensor; 4 - fitting for connecting the hose to the expansion tank; 5 - fitting for connecting the vacuum hose of the brake booster; 6 - connector of the crankshaft position sensor; 7 - ignition coils; 8 - oil level indicator; 9 - phase sensor; 10 - exhaust manifold screen; 11 - exhaust manifold; 12 - rear bracket for lifting the engine; 13 - clutch housing; 14 - oil drain plug; 15 - the place of connection of the fitting of the oil drain hose from the radiator; 16 - bracket for the left engine mount; 17 - coolant drain plug
Left side of the ZMZ-40524 engine
The right side of the ZMZ-40524 engine: 1 - coolant outlet pipe to the heater; 2 - branch pipe for supplying coolant from the heater; 3- knock sensor; 4 - point of attachment of the wire "-" KMPSUD and wire "-" from the car body; 5 - oil pump drive cover; 6 - receiver; 7 - inlet pipe; 8 - point of attachment of the wire "-" KMPSUD; 9 - top hydraulic tensioner cover; 10 - front bracket for lifting the engine; 11 - thermal valve; 12 - cover of the lower hydraulic tensioner; 13 - oil filter; 14 - bracket for the right engine mount; 15 - starter; 16 - clutch release fork support
Right side of the ZMZ-40524 engine
Front view of the ZMZ-40524 engine: 1 - crankshaft damper pulley; 2 - crankshaft position sensor; 3 - automatic tensioner; 4 - generator; 5 - fuel line with nozzles; 6 - fitting for connecting the hose from the adsorber; 7 - throttle module with electric drive; 8 - hose of the small branch of the crankcase ventilation; 9 - tube of the main branch of the crankcase ventilation; 10 - cover of the oil filler pipe; 11 - valve cover; 12 - branch pipe for draining coolant into the radiator; 13 - drive belt units; 14 - branch pipe for supplying coolant from the radiator; 15 - water pump with electromagnetic clutch; 16 - point of attachment of the wire "-" from the car body; 17 - oil sump
Front view of the engine ZMZ-40524
Technical characteristics of the engine and its systems
Type - Gasoline, 4-cylinder, 4-stroke, in-line, with an integrated microprocessor control system for fuel injection, ignition and air intake
Diameter cylinder and piston stroke 95.5 x 86 mm
Cylinder displacement 2464 cm3
Compression ratio 9.4
Cylinder order 1-3-4-2
The direction of rotation of the crankshaft (on the pulley side) is right-hand
Rated power at a speed of 4500±50 min-1 gross according to GOST 14846, kW (hp) 98.0 (133.3)
Maximum torque at a speed of 4000±200 min-1 gross according to GOST 14846, Nm (kgcm) 214.0 (21.8)
Power system
Distributed fuel injection - electromagnetic injectors into the intake pipe
Air filter - With dry replaceable filter element (installed on the car)
Ventilation system - Closed, forced, with vacuum valve
Lubrication system - Combined, with automatic oil temperature control
Oil filter - Full flow, non-separable, fine cleaning 406.1012005-01 or 406.1012005-02
Cooling system - liquid, closed, with forced circulation of liquid
Thermostat - two-valve, with the opening temperature of the main valve 82±2˚ C TS 107-05 or TP2-01 or TA107-05
Electronic control system - Controls air supply, distributed fuel injection by electromagnetic injectors into the intake pipe and ignition
Spark Plugs - DR17YC/A
Electrical equipment
DC, single wire, source and sink negative terminals connected to motor frame
Rated voltage, V 12
Generator - with built-in rectifier unit and voltage regulator 5122.3771 or 4052.3701000 (AAK 5572 14V 80A 11.203.412)
Starter - with remote electromagnetic activation and gear 6012.3708 or 405.3708000 (AZE2154 12V1,9 kWz9 11.131.262)
Coolant overheat alarm sensor - thermistor type ТМ111-02
Emergency oil pressure alarm sensor - contact type 2602.3829 or 4021.3829 or 6012.3829
Clutch - dry, single disc, with diaphragm pressure spring
Pressure in the lubrication system on a warm engine at the installation site of the emergency oil pressure sensor at an idle speed of 850±50 min-1, kPa (kgf/cm2), at least 98 (1.0)
The gap between the electrodes of the spark plugs is 0.7-0.85 mm
Coolant operating temperature 80...110°C
Minimum idle speed 850±50 min-1
Increased crankshaft speed 3150±50 min-1