We still couldn’t get around to it, but finally we made a full photo report on flashing and completely removing the EGR system on a Gazelle Next car with a Cummins ISF 2.8 Euro-4 engine
Based on our experience of communicating with them, the main troubles of owners of Euro-4 Gazelles with Cummins include:
- "eats like a bastard!"
Drives noticeably worse than the previous Gazelle with Euro-3 toxicity standards
The engine runs very harshly and unevenly, which mostly manifests itself under load.
EGR system, 99% of complaints about which are related to the heat exchanger. Antifreeze can go up to 5-7 liters per day!!!
Now all these troubles can be eliminated in the Speed Laboratory
We reprogram the car to the standard Euro-3 firmware, resulting in happiness:
Output characteristics: 148 hp and 360 Nm of torque
The exhaust gas recirculation (EGR) system was completely removed with the installation of plugs at the inlet-outlet of the heat exchanger and on the antifreeze channels
Added idle speed control function via cruise control button
Smooth and jerk-free engine operation even under load
Lower fuel consumption
When dismantling the USR, we remove 5 extra kilograms of iron and install original plugs on all technological holes
Plugs for the exhaust manifold and antifreeze hoses
Plug for the intake manifold from the EGR pipe
Reprogramming is done via the diagnostic connector without removing the control unit
Total operating time - 3-4 hours
Well, and our branded sticker on the body! :)
For more information about USR systems, watch our video:
The Cummins 2.8 engine (Cummins ISF 2.8L) is installed on vehicles manufactured by GAZ OJSC, in particular on commercial vehicles of the GAZelle Business and GAZelle NEXT family.
Peculiarities The timing drive is carried out by a single-row chain with an automatic tensioner. The chain is located on the flywheel side (the chain and tensioner are maintenance-free). The injection pump is driven through a gear from the crankshaft to reduce the load on the timing chain. The engine is equipped with devices to facilitate starting at low temperatures. To heat the air in the intake manifold, an electric spiral is provided. The fuel filter is also electrically heated.
The Cummins ISF 2.8 engine has very low fuel consumption - at a speed of 80 km/h it consumes only 10.3 liters of diesel fuel, at a speed of 60 km/h, which is the average intra-city speed, it reduces diesel consumption to 8.5 liters . Currently, the Kamins 2.8 engine is produced in China.
According to the manufacturer, the service life of the Kamens 2.8 engine is about 500,000 km.
Characteristics of the Cummins ISF 2.8 Gazelle Next engine, Business
| Parameter | Meaning |
|---|---|
| Configuration | L |
| Number of cylinders | 4 |
| Volume, l | 2,781 |
| Cylinder diameter, mm | 94 |
| Piston stroke, mm | 100 |
| Compression ratio | 16,5 |
| Number of valves per cylinder | 4 (2-inlet; 2-outlet) |
| Gas distribution mechanism | SOHC |
| Cylinder operating order | 1-3-4-2 |
| Rated engine power / at engine speed | 88.3 kW - (120 hp) / 3200 rpm |
| Maximum torque/at engine speed | 297 N m / 1600-2700 rpm |
| Supply system | with direct injection, turbocharging and charge air cooling |
| Resource | up to 500,000 km |
| Environmental standards | Euro 3, Euro 4 |
| Weight, kg | 250 |
Design
Four-stroke, four-cylinder diesel engine with an electronic Common Rail fuel supply system, with in-line cylinders and pistons rotating a common crankshaft, with an overhead camshaft. The engine has a closed-type liquid cooling system with forced circulation. Combined lubrication system: under pressure and splashing.
Cylinder block
The Cummins ISF 2.8L cylinder block is made of gray cast iron with milled cylinder liners. This results in less material consumption and greater strength. In case of wear, scoring, scratches or other damage, the liners can be repaired or replaced (possibility of relining).
Cylinder head
The cylinder head is cast iron, 16-valve. There is one camshaft installed in the cylinder head, which operates the valves in pairs through rocker arms (rocker arms of different shapes: they are short for the intake valves, long for the exhaust valves). A fuel injector is installed in the center of the cylinder. The cylinder head gasket is made from steel sheets (metal package) and does not require broaching.
Crankshaft
The crankshaft is made of malleable gray cast iron and is balanced. The crankshaft pulley with the crankshaft position sensor ring is one-piece.
| Parameter | Meaning |
|---|---|
| Diameter of main journals, mm | 74,0 |
| Diameter of connecting rod journals, mm | 59,0 |
Inlet and exhaust valves
All valves are made of heat-resistant steel with chrome-plated stems, have the same design, but are not interchangeable. All valves have a spherical well, the exhaust valves are distinguished by an engraved "C".
Service
Changing the oil in the Kamens 2.8 engine. The oil change interval in the Kamens 2.8 engine on Gazelle Business and Next cars is every 15,000 km (recommended 7-8 thousand km). The oil used is API CH4 standard, viscosity – 10W40. Shell Rimula R5 E 10W40 engine oil is filled from the factory.
The amount of oil in the engine is about 5.7-5.8 liters with replacement of the oil filter, the volume of the oil filter is 0.44 liters.
The catalog number of the oil filter for Gazelle Next with the Kamens engine is LF17356.
Adjusting valve clearances necessary for a mileage of 150 thousand km (from practice, approximately 80-100 thousand km). Adjustment unit - screw and nut. The intake gap is 0.25 mm, the exhaust gap is 0.5 mm.
In 2010, production of a new family of GAZelle cars began, which received the prefix “Business” to its name. Among the innovations of these cars is the inclusion of American Cummins diesel engines. In this article we will look at the most popular light truck GAZ-3302 with a Cummins ISF 2.8 engine.
Review of GAZ-3302 with Cummins ISF 2.8 engine
In 2010, the Gorky Automobile Plant launched production of a new family of GAZelle-Business cars - old modifications of GAZelles have undergone major changes, they have become more reliable and more modern. A few months later, sales of several more modifications of the GAZelle-Business began, equipped with an American-made Cummins diesel engine.
All main modifications of GAZelles are equipped with diesel engines - the GAZ-3302 onboard platform (also 330202, 33023, 330232, 33027 and 330273), the all-metal GAZ-2705 van (and 27057) and the GAZ-3221 passenger minibus (also 32212, 32213, 3 2217, 322173, 322132 and 322123). Since 2013, Cummins diesel engines have also been installed on new GAZelle-Next trucks.
In terms of their main characteristics, diesel modifications of GAZelle trucks do not differ from gasoline ones, however, the transmission has been redesigned (the gearbox and drive axles have different gear ratios, which is due to the use of low-speed diesel), changes have been made to the electrical equipment, to the cooling system of the power unit, to the exhaust gas release, etc.
To date, diesel modifications of these trucks occupy a significant share in the GAZ model range and are in stable demand among consumers.
We still couldn’t get around to it, but finally we made a full photo report on flashing and completely removing the EGR system on a Gazelle Next car with a Cummins ISF 2.8 Euro-4 engine
Based on our experience of communicating with them, the main troubles of owners of Euro-4 Gazelles with Cummins include:
- "eats like a bastard!"
Drives noticeably worse than the previous Gazelle with Euro-3 toxicity standards
The engine runs very harshly and unevenly, which mostly manifests itself under load.
EGR system, 99% of complaints about which are related to the heat exchanger. Antifreeze can go up to 5-7 liters per day!!!
Now all these troubles can be eliminated in the Speed Laboratory
We reprogram the car to the standard Euro-3 firmware, resulting in happiness:
Output characteristics: 148 hp and 360 Nm of torque
The exhaust gas recirculation (EGR) system was completely removed with the installation of plugs at the inlet-outlet of the heat exchanger and on the antifreeze channels
Added idle speed control function via cruise control button
Smooth and jerk-free engine operation even under load
Lower fuel consumption
When dismantling the USR, we remove 5 extra kilograms of iron and install original plugs on all technological holes
Plugs for the exhaust manifold and antifreeze hoses
Plug for the intake manifold from the EGR pipe
Reprogramming is done via the diagnostic connector without removing the control unit
Total operating time - 3-4 hours
Well, and our branded sticker on the body! :)
For more information about USR systems, watch our video:
Throughout its production history, Gazelle has been equipped with many powertrain options. So, there were ZMZ, UMZ, and other engine options. Of course, one of the most powerful options was the Cummins Gazelle engine, which was equipped with cars, mainly of the Business class.
Specifications
The Gazelle Business was equipped with a Cummins diesel engine, which performed quite well and was loved by drivers for its simplicity and reliability. But the installation of the Cummins internal combustion engine did not stop there, and with the release of Gazel NEXT in 2013, the tradition continued.
Main technical characteristics of the Gazelle power unit with a Cummins engine:
Design and principle of operation of the motor
It is necessary to start with the fact that the Cummins engine is very unpretentious to fuel. This became possible thanks to a new, modernized fuel purification system. The power unit is equipped with a new CommonRail fuel supply system. In this case, fuel is supplied directly into the combustion chamber under high pressure.
As for the gas distribution mechanism, everything is very simple and reliable. The cylinder head gasket consists of several steel sheets, which prevents it from burning out quickly, unlike other diesel engines.
The engine, which is mounted on the Gazelle, is equipped with a 4-valve gas distribution system, which ensures maximum technical characteristics and the required power. The timing chain has a chain with a tensioner, which ensures the reliability of the mechanism and sufficient strength. The camshaft is located according to the classical design.
Checking the valve clearances should be carried out every 80,000 km, but the valves need to be adjusted every 250,000. The valve clearance norm is: 0.38 mm for intake, and 0.76 for exhaust.
The fuel pump has a rather complex structure, which almost reduces the possibility of repairing it at home to zero. But, due to its reliability, it uninterruptedly provides high pressure, which is 1800 bar.
Also, an electronic controller is installed, which provides quality control of the fuel supplied to the injectors.
As for the cooling system, it is closed and can be configured for operation in different weather conditions. This becomes quite convenient since there is a significant difference in engine operation in warm and cold regions.
Power unit repair
Repair of the Cummins Gazelle engine is recommended to be carried out at service technical stations. Although the design is simple, the motor has a number of nuances that the owner of the vehicle does not even know about. Thus, the oil pump requires certain equipment in order for the repair to be high-quality. The same fate befalls the fuel pump, when repairing it it is necessary to clearly set the gaps.
The power unit is serviced every 15,000 km. This process includes operations to replace engine oil, oil filter, as well as fine and coarse fuel filters. Also, maintenance carries out diagnostics of the fuel pump and injectors.
Cleaning of injection elements is carried out as they become clogged, but the manufacturer recommends doing the procedure every 50,000 km. This will prolong the operation of the injectors.
Major repairs also require some equipment, so in this case, the principle does not work - we repair it ourselves. Although some motorists carry out restoration work with their own hands.
As in any case, you can disassemble the power unit yourself, but it is impossible to bore the block and crankshaft without special machines. Therefore, most owners of Cummins engines turn to car services. Although the engine has a service life of 500,000 km, they still do not last forever.
The crankshaft is bored to repair sizes of 0.25 mm, 0.50 mm and 0.75 mm. Further turning of the part weakens the hardness, which in turn increases the risk of the crankshaft breaking under heavy loads. The piston group is generally bored to a size of no more than 95.5 mm, and then a block sleeve is provided, which is quite convenient.
The block head can be completely rebuilt. At the same time, valves, guide bushings and seats are changed. Following the American experience, it is best not to knock out the old guide bushings, but to install K-line bronze bushings, which are placed inside the products. This allows you to avoid constantly boring the guide bushings and during subsequent repairs, simply replacing the bronze sleeves.
Conclusion
The Cummins Gazelle engine has established itself as a reliable and easily repaired power unit. The engine size allows you not only to obtain the necessary power, but also to be quite economical with an average consumption of 10 liters for every 100 km.
The engine design is quite simple, which allows you to carry out repair and restoration work yourself without any problems. As for the oil pump, turbine and fuel injection pump, it is recommended to repair them at specialized service stations, since the design is quite complex.