VIDEO
The 406 engine replaces the outdated power unit ZMZ 402. This is a gasoline internal combustion engine. The engine of the Zavolzhsky Motor Plant was produced until 2008. At first, the power unit was produced for the purpose of installation on Gazelle 3302 class cars, but later the Gorky plant decided to mount the 406 engine on Volga vehicles.
Structurally simple and easy to maintain, the 406 engine was an excellent power unit. The increased power and reduced fuel consumption allowed the power unit to blend harmoniously into the cars. In addition to the vehicles of the Gorky Automobile Plant, the 406 engine was mounted on the UAZ.
The first generation of the 406 engine had a carburetor injection system, but with the massive arrival of the injector, it was decided to improve the engine and adapt it for distribution injection.
So, let's take a look at the technical characteristics of the 406 engine:
Also, the Volga region produced a forced engine - ZMZ 40620D. On many vehicles, the letter D means that the power unit belongs to the category of diesel engines, but in the case of our factories, the situation is different - this is a designation of power.
Consider the technical characteristics that the ZMZ 40620D engine has:
As you can see, the only difference is the horsepower. The rest of the indicators remain unchanged.
All cars were already equipped with a 5-speed manual transmission. The device of the ZMZ 406 engine is simple. Unlike its predecessor 402, this power unit had two camshafts and 16 valves. The ignition system has also been adapted. The resource of the engine has increased to 250,000 km, instead of 150,000 km.
In addition to the standard motor, there are also a number of modifications. Modified 406 engine and characteristics:
ZMZ 4061.10 - carburetor engine, SZh 8 for 76th gasoline. Used on Gazelles.
ZMZ 4062.10 - injection engine. The main modification is used on the Volga and Gazelles.
ZMZ 4063.10 - carburetor engine, SZh 9.3 for 92nd gasoline. Used on Gazelles.
The service scheme for ZMZ 406 is quite simple. Motor, unpretentious to consumables. The power unit holds 6 liters of engine oil, but only 5-5.5 liters are required for a change. The oil filter is suitable for both the Gazelle and the Volga. The recommended maintenance interval is 15,000 km. But, in order to increase the resource, it is recommended to carry out maintenance for 12,000 km if the vehicle is operated on gasoline, and after 10 thousand km for gas.
The maintenance chart is no different from the 406, and looks something like this:
1000-2500 km or TO-0: oil and oil filter change.
8000-10000 km - TO-1: replacement of oil, oil and air filter, spark plugs, high-voltage wires, fuel fuel.
25,000 km - TO-2: oil change, oil filter.
40,000 km - TO-3: oil change, oil and air filter, spark plugs, high-voltage wires, valve adjustment.
55,000 km - TO-4: oil change, oil filter, fuel filter, timing chain and alternator belt replacement.
70,000 km - TO-5 and subsequent: oil and oil filter change.Every 20,000 km it changes - the fuel and air filter, the valves are adjusted. Every 50,000 km of run - replacement of the timing chain.
Routine maintenance involves replacing the lubricant and filters. Every 65-70 thousand km it is necessary to change the timing repair kit. A chain and a shoe are installed on the ZMZ 4062, as well as a drive and drive sprocket.
Every second maintenance requires checking systems such as valve train, powertrain ECM health, and sensors. The valve mechanism is adjusted after 50,000 km, or earlier, if necessary.
Often, by 70,000, hydraulic lifters fail, which need to be changed all together, since it is not known when the working ones will fail. The valve cover gasket is replaced every 40,000 km or when a leak forms from under it.
It is recommended to fill the engine with semi-synthetic oil marked 5W-30, 5W-40, 10W-30, 10W-40, 15W-40, 20W-40. To change the oil, you need 5.4 liters, which are poured into the power unit. As practice shows, most motorists perform motor maintenance on their own.
It is recommended to repair the Gazelle 3302 (Volga) engine in a car service, but most motorists do this process on their own. The simplicity of the design allows you to carry out all the work related to the restoration of the 406 engine with your own hands.
There were no particular malfunctions or problems due to engine operation. On some vehicle models, it was noticed that injectors quickly failed. This problem can be easily eliminated by replacing all injected elements. The chain of the gas distribution mechanism can last about 200 thousand km, but it happens that it does not take care of even 100 thousand km, as you are lucky.
Overhaul of the engine should be carried out after 250,000 km of run, but with proper operation and maintenance, it may happen that the engine will withstand 300,000 km. But if the driving style of "Alya" is a racer, then the resource of the power unit is significantly reduced.
Another problem is the native factory candles ZMZ 406. The way out of the situation is simple - to replace the candles with those produced by the Brisk company.
The capital of the engine takes place in several stages. The power unit is disassembled and diagnosed. Further, the process of purchasing spare parts takes place. Consider the main positions of the overhaul of the motor.
At this stage, work is being carried out to determine the hardness and thickness of the crankshaft journals, as well as its maintainability. So, if the part can be repaired, then the size of the necks is determined and the product is given for further processing. The same goes for the cylinder block. The liners are measured, and the repair size of the pistons is determined.
Pressing the cylinder head ZMZ 406 is the process of determining the presence of cracks in the housing. All openings on the head are closed, except for the coolant inlet, into which hot water or kerosene is supplied. Next, the specialist looks for leaks and cracks. If not, then the cylinder head is sent for repair, and if there is, then all defects must be welded.
Since the part is made of aluminum, argon welding is used. In garage conditions, motorists use cold welding to seal the holes in the housing of the power unit.
The cylinder block and crankshaft are bored. If the cylinders have already come out of the oversized size, then liners with a standard diameter of 92 mm are installed. Honing is becoming characteristic of a cylinder block - this is one of the processes of boring block cylinders using a special machine. The crankshaft is bored on a special unit, using high revolutions and a stone that polishes the journals.
The cylinder head also lends itself to a bulkhead. So, valves, seats, oil seals and cuffs often change.More than once, specialists have to replace the valve guides.
Today, replacement of the camshaft is quite common. This is due to the fact that the quality of the parts is not high and the camshaft journals wear out quickly. Therefore, when carrying out cylinder head repairs, this detail should be paid special attention to. If necessary, the working surface of the block head is sanded.
Assembly operations are carried out at a special stand. All parts are installed in the same sequence as they were dismantled. So, often the oil and water pump lends itself to replacement, a new set of gaskets is installed.
Thus, the resource of the motor is restored by 80%. If we count this in kilometer terms, then the power unit will be able to serve 180-200 thousand kilometers, with normal maintenance.
Some motorists are finalizing the ZMZ 406, that is, they are tuning it. There are two ways to upgrade. The first is mechanical revision, the second is software. In the second case, the electronic engine control unit is flashed to reduce consumption or increase power characteristics. In the first case, mechanical action is required to add power.
The car enthusiast will have to replace the camshafts, install T-valves, bore the combustion chamber, mount lightweight pistons, connecting rods and a crankshaft. Also, a complete adaptation of the cylinder head will be required. The power output will be about 200 horsepower, and the weight of the motor will decrease by 16 kg.
To mount the compressor, you will have to install a reinforced crankshaft and forged pistons. Garrett 28 turbine, manifold for it, piping, intercooler, 630cc injectors, 76mm exhaust, MAP + DTV, setting in January. Turbocharging the ZMZ 406 will allow the power unit to be fired up to an unrealistic 300-400 horsepower.
In this case, it is recommended for everyone to install a drain for cooling the motor. This will help to normalize the operating temperature of the turbo engine. The Brembo E317 kit, which is designed for installation on Russian Volga cars, is perfect.
Repair and tuning of the ZMZ 406 engine can be done by hand. The only nuance is boring and honing, which require special equipment. The motor itself has high technical characteristics and the required power, therefore it is suitable for installation both on a Gazelle and on Volga class light vehicles.
VIDEO
In the spring of 2012, Almaz, from Aznakaevo, approached us with a request to overhaul the jammed ZMZ 406 engine. he jammed. Spare parts (crankshaft, cylinder head and small parts) were also brought from another ZMZ 406 engine, in which the connecting rod broke off and the cylinder block was punctured. Actually, this motor was installed in the client's car (Volga), but after the connecting rod broke, there was no point in doing anything with the block.
Let's start to disassemble the engine that is jammed:
Remove the valve cover. There are a lot of lacquer and sludge deposits inside. We remove the camshafts and yoke. We find a piece of the chain. After removing the crankshaft pulley, we see the oil seal, partially crawled out of its nest - everything around it is filled with oil.
After removing the cylinder head, we observe the cylinders. The crankshaft still won't turn.
Remove the engine sump, unscrew the oil pump and connecting rod covers. The crankshaft wedges only after unscrewing the yokes of the main bearings. We dismantle the pistons with connecting rods from the block. After removing the front cover, we observe a crumbled timing drive - a piece of the tensioner shoe foot, broken dampers. The lid inside is damaged by debris.
The cylinders of the block are worn out, there are no more traces of the hone mesh, there is a depletion in the TDC zone of the piston. In the photo below - the collapsed tensioner shoe - one row of teeth is simply not there. Next, we open the cover of the oil pump drive and dismantle the drive shaft and gear. The teeth on both rollers are worn out. On the market, this pair was estimated at 3,000 rubles, which is very expensive, in the end, in agreement with the owner, they left her to live out her life.
The cylinder block is completely disassembled and prepared for boring:
While the block is being bored to a repair size and honed on a SUNNEN machine, let's move on to repairing the cylinder head of the ZMZ 406. We remove the hydraulic pushers and dry out the valves, then the head is sent to a chemical wash.
The valve seats have already sagged, which is a generic disease of the ZMZ 406 engine, especially when operating on gas. On gas fuel, the seats burn out and the valves gradually sag until the hydraulic compensator can no longer work out the gap and the valve stops closing completely - the compression disappears and the car is sent for repair. Usually, in such cases, the valves are trimmed in the services, but the author prefers to change the saddles.
The guide bushings from the factory put cast-iron "shorties" from the VAZ 2108 - they work poorly on gas and wear out quickly. We install bronze bushings of our own production instead of cast iron bushings - this material is guaranteed to “tolerate” gas fuel without wear in the “valve-sleeve” friction pair. The sleeve has a greater length than the factory one, which further increases its resource. In order not to overlap the channel, the outlet of the sleeve in the channel is made on a cone. 14.04-14.07 mm just fall into the nest. It is impossible to assemble the head in this way, for such cases we have repair bronze bushings with an increased outer diameter 14.10 vs 14.24 mm ... Such bushings will make it possible to produce a guaranteed high-quality overhaul of the head. In this case, the head was in good condition and the use of repair sleeves was not required.
We repair the cylinder head during general engine repairs and when replacing the cylinder head gasket.
It is very important to repair the head after the motor has overheated. During overheating, defects may occur that cannot be visually seen.
Therefore, you need to carefully do all the cylinder head repair operations. The operation of the engine largely depends on this. And this will save you unnecessary work and costs.
We look at the removal of the cylinder head in the article - "Replacing the head gasket ZMZ-406 GAZ-3110".
1. Unscrew the nuts 1 and remove the shield 5 of the phase sensor, the bracket 2 for lifting the engine and the exhaust manifold 6.
Remove the exhaust manifold gaskets.
Unscrew bolt 3 and remove the 4-phase sensor.
Unscrew emergency oil pressure sensors 7 and oil pressure gauge 8.
2. Loosen the clamp 1 and remove the hose from the idle speed regulator connection.
Unscrew nuts 2 and remove reservoir 3 from inlet pipe.
3. Unscrew the nuts 1 and remove the inlet pipe 2 together with the injectors and the fuel line (not shown in the photo).
Remove the inlet pipe gasket.
... and remove the back cover 2 of the block head.
Take out hydraulic tappets 1 for valves. It is more convenient to remove the hydraulic pushers with a magnet or a suction cup
Hydraulic pushers must not be interchanged, therefore, before removal, they must be marked so that they can be installed in their place during assembly.
The hydraulic pushers should be stored in the same position in which they are on the valves so that oil does not leak from them.
If the design of the puller does not provide for a valve stop, place a suitable stop under it.
Compress the springs with a desiccant.To make the spring plate easier to come off the crackers, you can strike a light blow with a hammer on the persistent bipod of the drying machine.
We take out two crackers with tweezers and smoothly release the springs.
Remove the top plate and two valve springs.
Remove the slinger cap with a puller.
Hook up with a screwdriver and remove valve spring support washer 1.
We turn the cylinder head over and take out the valve, marking the place of its installation, so that during the subsequent assembly the valve will fall into its original place.
Similarly, remove and mark the rest of the valves.
Press out the worn valve guides with a mandrel
Unscrew the plugs of the oil channels with a hexagon wrench “8”.
Especially for the article, a ZMZ 406 engine with high mileage was purchased. According to the old owner, he ran more than 600 thousand km in different conditions and was operated by different drivers, including pilots, for whom the hood is part of the car's skin, and not the engine compartment cover.
This engine was stupidly dismantled by bolts without any diagnostics of faults, since the mileage is large and everything has to be done. Having removed and cleaned the head, we saw: the valve seats, especially the exhaust ones, were sown, i.e. this will lead to a decrease or loss of compression. The photo shows that the valves sit deeper than the surface of the combustion chamber. By the way, for the owners of these cars and novice minders, this is a very serious malfunction for an engine with hydraulic lifters, which must be given due attention. We will not get carried away with measurements and numbers in this article, it is in the relevant literature so as not to miss some important points.
Here, too, you can see how the valves are recessed, although the image is of poor quality.
Accordingly, we are taking the block head to the workshop to replace the valve guides, valve seats and grinding, a block for cylinder boring for new repair pistons, and the crankshaft and washer for grinding. What was pleasantly surprised - the dimensions of the necks of the crankshaft were several hundred square meters below the tolerance, although the block inside was covered with a thick layer of oil carbon. But in principle, there is nothing to be surprised at - this is a factory quality.
While we are waiting for the processing results, there is time to figure out other details.
We check the wear of the bushings of the upper connecting rod head - as a rule, replacement is of course better.
We check the wear of the large sprocket of the intermediate shaft from the side of their contact, if there is a working out from the locking plate, then we weld it with a semiautomatic device and give it to grind -
Now, as practice shows, there will never be workings in this place, due to changes in the structure of the metal.
We check the flywheel, if there is production from the clutch disc, then we give it to the turner or grinder to the groove.
They brought the block - as you can see, in addition to boring, it was also polished due to a slight warpage of the surface during operation. If we proceed from practice, then used blocks after boring are nursed much more than new ones, since during the operation they received numerous heat treatments, metal shrinkage, etc.
Yes, it is imperative to grind the block with the front cover so that they lie in the same plane.
Now it should be well washed and all shavings removed from the oil channels.
After cleaning the block, we clean the crankshaft. Having unscrewed the crankshaft plugs, one often has to observe the following picture - the hole is almost completely clogged with oil carbon deposits. We clean, rinse, blow.
It happens that the edges of the plug cuts off, then you can weld a bolt to it and unscrew it.
So at 08 I rubbed the camshaft pastel covers into a class.
Will the ellipse in R.V.'s beds be affected? on the oil pressure in the head
Very informative, Thank you very much!
hello Sergey! thanks for the useful information you share on your channel! please tell me how many times you can grind the engine head. that is, how to determine that it is worn out so much that it is no longer possible to grind it!
hello Sergey. the ZMZ-406 and 405 engine is no different, and when will it be continued? Another question is the installation of the chain on the Moskvich 412 engine is installed according to the second mark on the crankshaft pulley.
and how to properly pull the chain on the Mosvich
hello, see the shafts, can I do something with them. I took a picture
Hello! Please tell me, when will the video on assembling the ZMZ 406 engine be continued?
I altered these yoke on the studs so that the thread in the head does not touch
There will be no continuation, the cylinder head was thrown into the trash. Dislike.
The need for overhaul of the ZMZ-4062 engine usually occurs after a run of 200,000-250,000 kilometers, depending on the conditions of its operation. By this mileage, the gaps reach values that cause a drop in power, a decrease in oil pressure in the oil line, a sharp increase in oil consumption over 0.25 liters per 100 kilometers, excessive engine smoke, increased fuel consumption, and increased knocking.
When to overhaul the ZMZ-4062 engine, remove and disassemble the engine, flush and clean its assemblies and parts.
Roughly, the gaps in the interface of the main parts of the ZMZ-4062 engine due to wear should not exceed the following values in mm:
Skirt of the piston-cylinder block - 0.25
The performance of the ZMZ-4062 engine can be restored either by replacing worn-out parts with new standard sizes, or by restoring worn-out parts and using new oversized parts associated with them. For this purpose, the release of pistons, piston rings, liners for connecting rod and main bearings of the crankshaft, guide bushings for intake and exhaust valves and a number of other parts of oversized size is provided.
To remove the ZMZ-4062 engine, the car must be installed on an inspection pit or overpass with general and portable lighting. The workplace must be equipped with a hoist or other lifting device with a lifting capacity of at least 300 kg.
The ZMZ-4062 engine must be thoroughly cleaned of dirt before disassembly. Disassembly of the engine, as well as assembly, is recommended to be carried out on a stand that allows the engine to be installed in positions that provide free access to all parts during disassembly and assembly. Disassembly and assembly of the engine must be carried out with tools of the appropriate size (wrenches, pullers, accessories), the working surface of which must be in good condition.
With an individual repair method, parts suitable for further work must be installed in their original places. To do this, parts such as pistons, piston pins, piston rings, connecting rods, liners, valves, hydraulic pushers and others, when they are removed from the engine, must be marked in any way that does not damage parts (punching, inscribing, attaching tags), or lay them on racks with numbered compartments in the order corresponding to their location on the engine.
With the impersonal method of repairing the ZMZ-4062 engine, it must be remembered that the connecting rod caps with connecting rods, the main bearing caps with the cylinder block, the camshaft bearing caps with the cylinder head are processed assembled and therefore cannot be disassembled. The crankshaft, flywheel and clutch are balanced separately at the factory, so they are interchangeable. The clutch housing is machined separately from the cylinder block and is also interchangeable. In hydraulic tensioners, dismantling of the housing with a plunger is not allowed.
The valve springs are dismantled using the ZM7814-5119 tool.In order for the valve spring plate to come off the crackers, you need to lightly hit the clamp bracket with the hammer handle with the hammer handle after compressing the springs. Remove the valves and mark them according to their location. The crankshaft pulley is removed using special tool 6999-7697.
Using the puller 6999-7683, remove the crankshaft main bearing caps together with the liners and thrust washers, checking the correct marks on the caps (1, 2, 4, 5). Remove piston rings from pistons with special tool 6999-7675. Remove retaining rings from pistons and press piston pins out of pistons using special tool 6999-7678 and thrust piece 6999-7927.
After disassembling the ZMZ-4062 engine, it is necessary to rinse all its parts, clean them of carbon deposits and resinous deposits. Clean the sealing surfaces of the cylinder block, cylinder head and covers from gaskets and sealant adhered and torn during disassembly.
Parts made of aluminum alloys (cylinder heads, pistons, covers, etc.) must not be washed in alkaline solutions, as these solutions corrode aluminum. The following solutions are recommended for cleaning engine parts ZMZ-4062 from carbon deposits.
Soda (Na2CO3), g - 18.5
Video (click to play).
Caustic soda (NaOH), g - 25
