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In the spring of 2012, Almaz, from the city of 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 do not work well 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.
The clutch is advised by LUK. You can put a Sachs, but it is tougher than the Luke. On the chains, if you find it, the gold series ZMZ. They come with a set. And they have single-row sprockets, like on diesel engines.
The set of gaskets for the top cover is from Herzog. Retains oil spills well enough.
But now I took the clutch at 4063 - Valeo. According to my subjective indicators, it is also a worthy design.
The set of gaskets for the top cover is from Herzog. Retains oil spills well enough.
But now I took the clutch at 4063 - Valeo. According to my subjective indicators, it is also a worthy design.
Thank you. Now I have looked at the prices for the clutch, and so VALEO is more expensive than LUK by 200-300r.
[quote name = ’Vladison’ date = ’6.9.2012, 9:28 ′ post =’ 760881 ′
But now I took the clutch at 4063 - Valeo. According to my subjective indicators, it is also a worthy design.
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 the 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: changing the oil, oil filter, fuel filter, replacing the timing chain and alternator belt.
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 the valve train, the state of the powertrain ECM, and the health of the 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
less harmful emissions in the atmosphere;
higher than the engine efficiency, since the fuel is supplied at the right time and in the right amount, in addition, part of it does not run from the fuel tank up to the cylinder;
from the second point it will flow out that the injector motor uses less fuel (on the average 11 liters per 100 km, against 13-15 on a carburetor);
It also results in the fact that the engine develops more power (130 hp versus 100 in a carburetor).
do not float cold revolutions;
there is no need, as a carburetor, to periodically adjust the injector;
in winter it is possible to run without heating the motor.
Economy of means - gas is cheaper than gasoline.
Reducing the risk of detonation, since the octane gas is higher.
The best lubrication of dry parts in the cylinder - the gas does not wash off the oil film from the cylinder walls, unlike gasoline.
it is not necessary to spin the starter for a few seconds and press the gas pedal (although the motor is hot);
As a note, it will give out large revolutions (about 2000 rpm) and a few seconds.
The controller does not tell you that there is a problem in the system.
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The engine 406 injector runs out and doesn’t start, and until then it was running out of gear and was running low.
the same problem. the starter is spinning but doesn’t have to know what to do
The start is spinning well, too. Akym new, another will start without a problem. The engine changed the timing chain, fills the candles. Spark, the diagnosis said change the air sensor, changed - also the same !! (
I have a glox engine in a preheated state, it did not start warm, I exited only with a gas pedal, changed the TOZH sensor and everything worked like a chuck.
A worker is a disease of this engine
Exal to the store. I did, I turned on the neutral - the engine worked fine, because something got inhibited and ignored. I tried to get it - it doesn’t cool, it doesn’t start from the back. What could be the reason?
Doesn't develop full power on gas, on gasoline - ok, why?
Gazelle 2009. The 100 threw out and delivered 406 injector. The machine uses up and the gas consumption is about 22-25 liters. What is the problem?
y me 406 carburetor, want to send injector
What is the best oil to fill the 406 engine with an injector?
Made a major overhaul of the engine 406 Ing. After assembling, we made a cold rolling. Then we installed the machine, after running at cold pressure 2, after heating the pressure drops to 0. Tell me what's wrong?
y me worked 406 engine injector, ran out of gasoline. Stopped at night, hit the frost. Bring the gasoline, started to start, the battery, charged it, did not start. He shoots, fires at the muffler. I checked the chain, the marks are in place, but not start. What to do?
There was a problem, maybe someone hit, please answer.
On the ZMZ406 engine, I changed the upper hydraulic chain tensioner. The machine has started to start. What's the problem?
It is hard to start up with full gas, when the gas is released, it wastes and glosses, charging at low turnover does not work, what to do?
Guys, tell me what happened? The check is on and you pick up the turnover, and if you pay it for a long time
It works ideally for cold, as it raises up to 90 degrees during operation, it goes dark, and for cold works, what to do?
Guys, I'm such a problem. Scales the pressure arrow even when the ignition is off
In menya volga 105 c dvc 406 inzhektop, tozhe ctolknylcya c etoy zhe ppoblemoy, bez pedali gaza ne zavoditcya voobsche nA xolodnyyu c gpexom popolam and tpoit, zhectoko smoke valit of tpyby, ppogpeetcya, pepectaet go smoke zaglyshish, poppobyesh zavecti - voobsche ne start. Look into the floor, you twist, it would be enough and the same would be covered, suggest what might be
Wait, please! Bolga 31105 406 did not start, sent new candles, wires. No sparks a candles dry. Does not supply benzine to the candles. What could be the reason?
load, gas in the floor, trek under the top of the valves, the rotation will jump, the engine is running, the check is on, the lamp will start up at the temperature and pressure
Cepega , the distribution of the shaft he gave you incorrectly Aptyp , on a gas loses 30 percent of power Oleg , spread the shafts by indicator Jupa , trust the motor, the car is better even in the financial sense Sanya , zik 10 to 40 or ecco 10 to 40 Dmitry , water on fortsinkax - in a warm place of the machine Igop , knocked down the tags to spread the shaft Michael , side flaps on the injector Vladimir , the distribution of the shafts must be correctly aligned according to the indicator from the first cylinder
Does not operate the fuel pump and does not operate the taximeter
The engine picks up speed very flat, what could be the matter?
Ha a cold start, it works well and starts to waste, runs out, the engine jumps, and then it goes dark for 5 minutes, help, what to do?
Wait, it goes well on cold, but as it gets warm up to 60, it loses turns, you give it to the gas, so it develops with difficulty, what can it be?
406 injector does not start. Beginning delivered the car, and in the morning there was not a lot of frost. Twisted, twisted, almost cured, but the battery was charged, it didn’t fill it, it doesn’t fill the candles. I checked, the chain is not on the mark. I got up, changed the candles, the water, but not in any plant. Cats for work. Help, I don’t know what to do.
Please, do you think that behind the hoop, over the motor, are they in a vapor with accessories? Do not start, dry candles! You put it in the cylinders, roll it up and go dark again! Where is the relay and its adapter? Thank you for your help!
does not start, the engine fills the candles, sprinkles, but it’s kind of weak.
Wait, please, what should be the company and how to measure it correctly?
Wait! From the morning it is warmed up, the speed is 1100, less does not fall. I changed everything, the diagnostics does not show anything, I remove the clamp everything in order, I already started to remove the clamp, the internal combustion engine 406 injector.
Problem, I start the machine from the morning, heat up the turns 1000-1100 at 80, remove the clamp and put on the clothes after a couple of minutes, get the turns 860.
The expander emits a toco
The engine 406 is an injector, refills for cold, at a heating of 47/50 degrees everything is normal. Tell me what the reason is. The diagnostics determined that everything is in the norm.
And y me such a problem and now it has become a good plant, although earlier at 42 I started
The engine runs out and does not start (on cold), everything is heated in order. After reading a lot of formats, searching through dozens of sites, I identified 3 main reasons: temperature sensor, fuel pressure regulator, and lack of performance
Uaz Xantep ZMZ 406, toplivnaya cictema nopm, vce Po diagnoctiki nopm, kpome tolko togo chto net pazpyazheniya 0 vo vpycknom kollektope, ne mogy nikak nayti ppichiny nA xoloctyx ctoit pabotaet povno, DURING time you press nA gaz bydto topliva ne xvataet ne pazvivaet obopoty ctpelyaet! ! Suggest what other reasons, in addition to the fuel system and the control, could be sensors of all norms?
Uaz patriot re-styling, engine 409 (406), only at a temperature of 40 degrees does not want to start from the first time (start only after 4-5) The check is not burning, and also the diagnostics does not show anything. Changed the temperature sensor of the cooling fluid and no smell! What could be?
What features can be replaced instead of ZMZ 9261 from SIEMENS DEKA?
guys, tell me how many links on the camshaft 16 valve injector
You will know: what types of supplies are in your car, where they are found, how to check their operation. And in the end you will receive a few tips on how to replace them.
A person is painfully aware of the car's strips. First of all, due to expenses for replacement. This article will tell you how to replace the pump with a BAZ 2109.Having read it, you can do it yourself without any effort, which will save money.
Video (click to play).
Those who are interested in the 21126 engine, want to know about its technical characteristics, problems with which you can use when operating, designing, drawing and reading Then you will find the answers to your questions.
