DIY cylinder head repair Zmz 406

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

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.

Video (click to play).

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 it is not possible to 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 relation to the peculiarities 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!