Do-it-yourself gas repair 31105 zmz 406

In detail: do-it-yourself gas 31105 repair ZMZ 406 from a real master for the site my.housecope.com.

CAR REPAIR VOLGA GAZ 31105

section 1
ENGINE ZMZ 406
device and description of the ZMZ 406 engine
oil and oil filter change
tension adjustment and replacement of the accessory drive belt
replacement of the tensioner roller of the accessory drive belt
replacement of the front crankshaft oil seal
replacing the rear crankshaft oil seal
removing the oil cooler
removing the tap and oil cooler hoses
intake manifold gasket replacement
replacement of exhaust manifold gaskets
removing camshafts
replacement of hydraulic lifters
removal and installation of hydraulic chain tensioners
disassembly of the drive of the gas distribution mechanism
disassembly of the oil pump drive
removal and repair of the cylinder head
replacement of engine mounts (cushions)
removal of the ZMZ 406 engine
repair of the ZMZ 406 engine

section 2
ENGINE CONTROL SYSTEM ZMZ 406
diagnostics of the engine management system, error codes
replacement of relays and fuses of the engine control system ZMZ 406
replacement of the electronic engine control unit ZMZ 406 on the Volga GAZ 31105 car
checking and replacing the synchronization sensor
checking and replacing the camshaft position sensor
checking and replacing the throttle position sensor
replacing the MAF sensor
checking and replacing the coolant temperature sensor
checking and replacing the air temperature sensor in the intake manifold
check and replacement of the knock sensor
replacement spark plugs
checking and replacing high-voltage wires
checking and replacing ignition coils

Video (click to play).

section 3
POWER SUPPLY SYSTEM OF THE VOLGA GAZ 31105 ENGINE
design description
replacement of the filter element of the air filter
replacing the fuel filter
replacing the fuel intake filter
throttle actuator adjustment
checking the fuel pressure in the power supply system
removing the fuel rail and injectors
check injectors
removing the fuel pressure regulator
checking and replacing the idle speed regulator
removal of the throttle assembly
removing the receiver
removing the fuel pump
removing the fuel module
removing the fuel pump and fuel gauge sensor
removing the fuel tank

section 4
EXHAUST GAS RELEASE SYSTEM
design description
replacement of suspension elements of the exhaust system replacement of elements of the exhaust system

section 5
ENGINE COOLING SYSTEM
design description
coolant change
replacing the coolant drain valve
replacement of temperature gauge sensors and coolant overheating warning lamp
removing the expansion tank
checking and replacing the thermostat
replacement of the sensor for turning on the electric fan
removal of the electric fan
removing the radiator
replacing the coolant pump

section 6
CLUTCH
design description
adjustment of the clutch release drive
bleeding the clutch release hydraulic drive and changing the working fluid
replacing the hydraulic hose
replacement of the clutch master cylinder
replacement of the clutch slave cylinder
clutch fork replacement
replacement of driven and master disks

section 7
TRANSMISSION
design description
Change of oil
Extension oil seal replacement
removal of the gearbox
replacement of the input shaft oil seal
replacement of the front bearing of the input shaft
gearbox repair

section 8
DRIVE GEAR
design description
universal joint lubrication
removing the propeller shaft
propeller shaft repair

section 9
REAR AXLE
design description
semi-axle bearing lubrication
Change of oil
semi-axle removal
axle shaft oil seal replacement
replacement of the oil seal of the main gear drive gear
rear axle repair
adjustment of the main gear by the contact patch of the teeth
removal of the rear axle

section 10
FRONT SUSPENSION
design description
front wheel alignment angles
hub bearing adjustment
shock absorber replacement
replacement of the upper ball joint
replacement of the lower ball joint
spring replacement
removal of the upper arm
removal of the lower arm
replacing the anti-roll bar
removing the anti-roll bar
replacement of hub bearings

section 11
REAR SUSPENSION
design description
replacement of spring anti-squealing gaskets
shock absorber replacement
removing the anti-roll bar
replacement of silent blocks and pillows
spring removal and disassembly

section 12
STEERING
design description
replacement of working fluid and filter element
bleeding the hydraulic drive of the power steering
checking the technical condition of the steering
pendulum arm lubrication
steering gear adjustment
lubrication and adjustment of steering rod joints
removal of the tie rod end
removal of steering linkage rods
removal and disassembly of the pendulum arm
removing the steering gear
flushing the flow and safety valves of the power steering pump
removing the power steering pump
removing the steering wheel
removing the steering column

section 13
BRAKE SYSTEM
design description
bleeding the brake system replacing the brake fluid
adjustment of the drive of the rear wheel brake pressure regulator
parking brake drive adjustment
replacement of the brake pads of the front wheels
front wheel brake hose replacement
removing the front wheel brake caliper housing
removing the brake disc
replacement of brake pads of rear wheels
rear brake hose replacement
Replacing the wheel cylinder of the rear wheel brake Removing the rear wheel brake pressure regulator
replacement of the brake master cylinder
replacement of the vacuum brake booster
parking brake cable replacement
removing the parking brake mechanism
removing the pedal assembly

section 14
ELECTRICAL EQUIPMENT
design description
checking dead circuits
checking electrical circuits under voltage
replacement of fuses and relays
accumulator battery
replacement of the contact group of the ignition switch

section 15
GENERATOR
design description
checking the generator on the car
replacement of the generator voltage regulator 2502.3771
replacement of the generator voltage regulator 3212.3771 / 9422.3701
removing the generator
generator repair 2502.3771
repair of the generator 3212.3771 / 9422.3701

section 17
LIGHTING, LIGHT AND SOUND SIGNALS
replacement bulbs headlight unit
headlight unit adjustment
removing the headlamp unit
removing the headlight electrocorrector regulator
removing the fog lamp, replacing the lamp
fog lamp adjustment
removing the central light switch
removal of the steering column switches, alarm switch
removing the side turn signal, replacing the lamp
replacement of the brake light switch
replacing bulbs in the rear lamp, removing the lamp
Replacing the reversing lamp switch
removal of the additional brake signal lamp, replacement of lamps
removal of the interior lighting plafond, replacement of the lamp
removing the light under the hood, replacing the lamp
replacing the glove compartment lamp
removal and adjustment of the sound signal
removal and disassembly of the switch of sound signals

section 18
WINDSHIELD CLEANER AND WASHER
removing and disassembling the windshield wiper
removal of the electric pump and washer nozzles

section 19
DASHBOARD
checking control devices and their sensors
removing the instrument cluster
replacement of instrument cluster lamps
replacement of the speed sensor
replacement of oil pressure sensors
replacement of the fuel level indicator sensor

section 20
BODY
design description
removing the engine mudguard
removing the front bumper
removal of the lower front panel
removing the radiator grille
removing the hood
removing the hood lock
removing the hood hinge
removing the front fender
windshield replacement
rear window replacement
removal of the tunnel floor cover
removing the instrument panel
adjustment and removal of the front seat
removal of the rear seat
removing the side rear-view mirror
removing the front door trim
removal of the lock and handles of the front door
removing the glass of the front door
removing the front door window regulator
removing the front door
removing the rear door trim
rear door glass removal
removing the rear door window regulator
removing the rear door lock
removing the boot lid lock
removing the trunk lid
removing the tailgate hinges
removing the spare wheel mounting frame
removing the rear bumper

section 21
HEATING AND VENTILATION SYSTEM
design description
replacement of the crane and electromagnetic
heater valve (pneumatic actuator)
heater tap replacement (mechanical drive)
replacing the heater fan resistor
replacement of the electronic speed controller of the heater electric motor
removing the heating and ventilation control panel
replacement of the electric fan of the heater
removing the heater
heater radiator replacement

DIAGNOSTICS OF MALFUNCTIONS OF THE VOLGA GAZ 31105 VEHICLE

Repairing the engine of any car is an extremely responsible and serious operation that requires a qualified approach. Along with this, with a great desire and appropriate knowledge, it is quite possible to cope with the conduct of the event in question on your own.
After reviewing the information below, you will get a complete picture of self-repairing a ZMZ-406 engine for GAZ, including the preparatory stage, disassembling the engine and reassembling it. The information provided will allow you to save a lot on the services of specialized workshops and be completely confident in the quality of the work performed, because each stage will be controlled by you personally.
Preparation of tools for repairing 406 engine

First of all, prepare the site for further unfolding of all elements. There should be enough space so that you can conveniently arrange the parts in order - this will make reassembling the motor much faster and easier. If there is not enough space, label the items in any other suitable way. Mark and remove wires in the same way.
Remove the hood and disassemble the wiper panel (this will be more convenient). Cover these parts with suitable material to protect the front fenders from damage. You can disassemble in any sequence convenient for you. For example, to make the engine as easy as possible to remove from the engine compartment, you can remove almost all available attachments. Most craftsmen prefer to disassemble until only a block with a piston remains. There is no need to detach the power steering pump from the hoses - you just need to tie it up or put it somewhere.
After removing the motor, inspect the area under the hood for damage and dirt. Wash everything as thoroughly as possible with a metal brush and kerosene or gasoline.

Measure the clean block and crankshaft. Boring may be necessary. If you do not have the appropriate skills, it is better to take the items to the factory or to a specialized workshop - there they will check everything and waste it to the conscience. At the same time, you can give the flywheel and the clutch basket to the specialists.In the workshop, the flywheel will be checked for runout and, if necessary, will be trimmed at the place where the clutch disc fits, after which it will be balanced in combination with the basket and the crankshaft. For our beloved GAS, this service is very useful and necessary.
Buy connecting rod and main bearings, rings and pistons by size. After removing the parts from the bore, rinse and blow them again. Armed with a 14th hexagon, unscrew the plugs of the dirt traps, thoroughly clean everything there, and then put the plugs back. If you cannot unscrew the plugs of the block and the head (the 8th hexagon is suitable for them in size), do not try to do this with great efforts - you can damage the threads. In such a situation, it is enough to blow through the oil channels.

so that blind threaded holes are completely free of antifreeze, oil and various contaminants.
Be sure to check the cylinder head in terms of its fit directly to the block, the condition of the guides and valves, replace the valve stem seals. To grind all the available valves (and there are already 16 of them here) is not the most fun task. To make things easier for yourself, you can take the head to the factory or to a specialized workshop.
After completing all the above activities, you can start assembling the 406 engine.

Important! Wash hands and tools thoroughly before assembling the engine. Carefully inspect the condition of the nuts, bolts and studs for edge and thread breakage or other damage. Be sure to replace suspicious fasteners with new ones - you will not spend a lot of money on this, but the consequences of using low-quality fasteners may not be the most pleasant.
When tightening the fasteners, do not apply too much force - the thread breaks off extremely easily, but it is extremely difficult to recover. For additional sealing of gaskets, a sealant, as well as shellac varnish, is excellent. Pre-degrease the mating surfaces for the gaskets with a solvent or acetone, then wipe them dry.
To some, the above preparatory measures may seem too long and useless, but as a result, the already assembled engine will remain clean, and you will generally forget about leaks.
The assembly process itself consists of several technological steps. Perform each of them sequentially, and the final result in quality will not be inferior to the work of a qualified master.

Step 1. Take the engine block and lay it upside down. The dipstick tube will most likely get in the way at this stage, so it is best to install the unit on some suitable and, most importantly, reliable stand. At the same stage, you need to install the main bearings equipped with holes (here they are upper) and lubricate the whole thing with oil. Install persistent half rings on the 3rd support Crankshaft... For work, half rings that do not have antennae are used. Installation is carried out so that the anti-friction layer "looks" outward.

Assemble all the elements under the hood of the car, observing the reverse order of disassembly.
Fill in your preferred butter... Don't forget about the coolant. Make sure there are no leaks of any kind. Free the relay from the block, crank the engine with a starter - this way you fill the oil system. In the process of performing this stage, be guided by the readings of the pressure sensor.
Finally, install and connect the rest of the elements and start the car. Check for leaks. Check oil pressure, temperature and other relevant parameters. Resolve any problems found immediately.You just have to let the engine idle for several hours, periodically checking its condition, after which the engine can be taken into permanent operation, following all the requirements for running in a new machine.
Happy work!

No car repair is complete without the help of a neighbor, friend, or referring to literature or the Internet. Previously, there was only one way to independently understand the structure of any mechanism or machine unit - this is the study of the necessary literature. Now, thanks to high technologies for transmitting data over a distance (Internet), there are more opportunities.Car design Volga GAZ 31105Owners of GAZ-31105 vehicles are no exception. Maintenance and operation of this vehicle requires the necessary information to be freely available. It's one thing when a rusty penny is being repaired - half of our country knows the structure of this car like the back of their hand. A Volga with a Chrysler engine is a more advanced vehicle in which a large number of electronics (there are more than ten sensors, and each affects the correct operation of the car as a whole).
Image - Do-it-yourself gas repair 31105 zmz 406

repair and operation of the engine;
repair and operation of the gearbox;
repair and operation of the fuel injection and supply system;
repair and operation of the power steering (GUR);
repair and operation of the brake system;

Diagram of the device and design of the brake system GAZ 31105

Thanks to the information received, you will learn how to independently find problems in the operation of the car and determine the simplest and most effective method of troubleshooting. You no longer have to turn to the paid services of specialists from specialized service stations. You can do most of the work (which does not require special devices and devices) with your own hands, turning to this manual for help only.

Cold rainy autumn days have come, and the heater system of your GAZ-31105 car is barely blowing and is only good for keeping the glass from fogging up? Well, what can we say about the operation of a car with the onset of frost. Nothing wrong with that. You just need free time, "straight" hands and a manual for the repair of your car.It is not so difficult to understand the design of the system and the principle of operation of the stove. It is worth starting to look for the cause of the malfunction, and, quite possibly, there will simply be a blown fuse, changing which you will restore the stove to work properly and return the heat to your car.Despite the fact that it is made using high-quality metal and extra durable rubber, as a result of car operation, you need to periodically check the condition of the 31005 gas suspension.It looks like the front suspension of the car Volga 31105Volga "Chrysler" is no exception, the car is much heavier than VAZ models, thus, if you hit an obstacle, the risk of "getting" for repairs is very high.For a routine inspection and replacement of worn-out parts, a pit and knowledge of the procedure for removing some elements will be required. You can glean the missing knowledge about the structure by contacting the maintenance manual for this car for help.Advice! It is very convenient to check the condition when crossing a large bridge. As a rule, the asphalt on it is covered with small cracks, passing along which you will hear the noise of your car's suspension.Rear suspension Gas 31105At first glance, it seems that engine repair is a very difficult process and cannot be done on your own. Moreover, a foreign-made engine from the Chrysler company. In fact, you only need help to make a repair if you are going to remove it completely, for example to replace bushings or a piston. You will have to call an assistant in order to get him out from under the hood.Further, following the descriptions of this manual, you can do the work yourself.To remove the motor, you need to disassemble almost the entire engine compartment.

drain and remove interfering pipes of the cooling system;

remove the ignition coil;

pick up the power steering tube;

remove several sensors that interfere with the disassembly of the engine.

After completing the necessary work to repair the motor, as very often happens, unnecessary parts remain. In order to avoid such a situation, it is recommended to take your time and lay out the parts from one mechanism to one side, the other to the other. In addition, in case of any question, you can always look in the manual about the correspondence of a given part to this mechanism.

You can perform even such a complex procedure as adjusting the valves of an internal combustion engine yourself. Only for this you need to purchase a special adjustment device. Well, no additional equipment is needed to replace rings, pistons, gaskets, liners or crankshaft.

Probably, with every car owner at least once in his life, there have been curious cases associated with a car breakdown. For example, after long attempts to start your "iron horse", after listening to the advice and recommendations of your neighbors in the garage, you call a car electrician. Arriving, he finds the cause of the breakdown within five minutes. It turns out that the fuse has blown or the contact has oxidized. You will laugh at yourself, but give the money for the challenge.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.

The turbine and air blower are located on the same axis together with the impeller, inside the exhaust manifold.

That is, the injection engine does not need to spend energy on spinning up the compressor, due to which its efficiency does not decrease, but, on the contrary, increases.

However, turbocharging also has several drawbacks, although they are not so significant.

The first is low efficiency at low revs. This can be explained by the fact that at low rpm less exhaust gases are emitted. The compressor starts to work at full capacity at high engine speed.
The second disadvantage that should be noted is the so-called "turbo lag" effect. A certain period of time passes between pressing the gas and the start of the compressor's full operation, but the designers are constantly striving to reduce this time by reducing the weight of the turbine units.

Video (click to play).

We talked about increasing the power of the ZMZ 406 engine with an injector, good luck on the road!