Do-it-yourself gazelle engine repair

In detail: do-it-yourself gazelle engine repair from a real master for the site my.housecope.com.

Engines, ZMZ 406 are in-line, four-cylinder, carburetor with microprocessor ignition control.

Repairing a 406 engine is a serious and responsible operation. If you do not have enough experience, it is better to contact the station. How to repair a 406 engine is described in detail in the car manual.

The list of parts to be replaced is up to each individual.

a set of tools (keys, heads, cranks), a torque wrench, etc.

Disassembling the motor will require a lot of space to place all the parts, this will help during installation when everything is at hand. We also remember, or better write down, the wires being removed. To avoid interfering, remove the hood and wipers, so as not to damage, cover the front fenders. For easy removal of the motor from the motor, you can leave it on, just put it somewhere.

After removing the engine, you can wash it under the hood and you need to inspect the damage to the wires.

In order to make the boring of the block, we take it to the factory with a flywheel and a clutch basket. For a car, this is a completely unnecessary process.

Having wasted, washing the parts with kerosene, we unscrew the four plugs. It is not permissible to find oil, antifreeze, debris in blind threaded holes. the liquid does not compress and the threads are damaged. We check the cylinder head, i.e. the plane of contact with the block, valves, valve guides, we change the valve stem seals.

It is not superfluous to take the cylinder head to the factory for grinding, since it is too dreary and not convenient to grind 16 valves. When everything is ready, you can start assembling the engine.

Video (click to play).

It is important to work with clean hands and tools when assembling. Bolts, nuts, etc. with a bad thread, we replace it with new ones, it is better not to save. It is necessary to tighten without effort - the thread can easily break off, and the restoration process is very difficult. It will not be superfluous to grease all the gaskets with a sealant, and wipe the places of contact with them with a solvent.

As a result, the motor will be clean during operation, nothing will leak.

We put the cylinder head on, insert the persistent half rings KV with an antifriction layer outward.

We close the crankshaft with covers. Do not mix up the covers. We also install the connecting rods. We tighten the cover bolts with a key of 10-11 kgf • m.

We rotate the KV for counterweights, it should rotate easily, by hand, and not with the help of a crowbar.

Next, we install the rear oil seal in the holder and screw it to the cylinder head, not forgetting about the gasket. We lubricate the outer part of the oil seal with a sealant, and fill the space between the working edge and the boot with lithol.

We tighten the flywheel. The flywheel on KV is put in only one position. A special washer is installed under the bolts. To lock the crankshaft, you need to stick a hammer handle between the block wall and the counterweight.

We put a spacer washer and a new bearing toe of the input shaft of the gearbox.

Further repairs of the 406 engine can be conveniently carried out by placing the block on the flywheel.

We collect the connecting rod-piston group. The new piston kit includes pins and retaining rings.

Before assembling the piston, it is necessary to heat up and lubricate the finger with oil. We immediately install one retaining ring in the piston, be sure to make sure that they sit in their grooves in the piston so as not to set the finger further than necessary. The lettering on the piston in front and the protrusion on the lower end of the connecting rod must be in the same direction.

We put the retaining rings, be sure to make sure that they sit in their grooves in the piston. There is a diagram of their installation on the packaging of the rings.

We collect the connecting rod and cover.Be sure to lubricate the cylinders in the cylinder head with oil, make a crimp for the rings.

We put the block out with the first and fourth cylinders. And install the pistons back.

Before tightening the connecting rod, do not try to twist the piston, otherwise break the ring locks. We install rings in the block, covers, tightening with a torque of 7-8 kgf • m.

Turn the block 180 ° again.

We do the same with 2 and 3 cylinders. Result:

The rotation of the block should be effortless.

Next, we install the dowels, KV stars, an oil seal.

We insert the intermediate shaft, lubricating, back, the oil pump drive shaft. We close the lid.

Tighten the timing chain sprocket bolts.

We put the block on the stand with the pallet towards the top.

We install the clutch, not forgetting to center the disc with the input shaft.

We fix the damper with bolts and put on the upper chain.

We tighten the cover with the gasket, the water pump.

We tighten the 6-sided oil pump, then install the pump and close the sump, then the clutch housing and amplifier.

We attach the starter, water flange and knock sensor.

We install brackets for pillows, power steering.

We put the front oil seal, lubricating the front pulley similarly to the rear.

we install the cylinder head, tightening the bolts first with a torque of 5 kgf • m, then 15 kgf • m.

We install in place the hydraulic valve compensators, having lubricated them with oil, a common front cover with plastic persistent half washers.

Then the 3rd and 7th. Do not forget: inlet - 1,2,3,4, and outlet - 5,6,7,8.

The bosses, on which the numbers are stamped, are directed towards the edges of the head.

We squeeze the 3rd and 7th and tighten all other covers with 3 kgf • m bolts.

Using the key, we check the rotation of the shafts.

The shaft pins must be on a horizontal line and point in different directions.

We put an exhaust sprocket on the chain, preventing the upper part of the chain from sagging.

Install the upper hydraulic tensioner in the same way as the lower one.

We close the covers: front and rear, fill the grooves of the slinger in the cover with sealant, screw it back.

We tighten the valve cover.

That's it, now the motor is completely ready for installation on the car.

That's it, the repair of the 406 engine is over.

It remains only to install it on the car.

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

Read also: DIY repair 2110

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 are used that do not have antennae. 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!

We also examined the chains (Euro 4 “Ideal phase” set of Progress production, mileage of about 50 t.km) - the chains and sprockets practically did not wear out, only the shoes had a slight wear of about 0.5 mm. But all the same, the chains will be replaced (so as not to climb again later). There will be a set of Euro 3 “Ideal phase” with shoes from the same Progress.The Sachs clutch passed about 120 t. Km. Naturally there is wear and tear, but the clutch is still similar. I will leave it, replace only the release bearing.

The cylinder head is to be repaired today. Oleg promised to trim the channels, because the quality of the casting leaves much to be desired. However, more on that next time. To be continued.Gazelle repair has many features, and you should know about them in advance before starting any work. The first thing to understand is that common breakdowns are described in the user manual, therefore, after reading this booklet, you can not only identify, but also successfully eliminate most of the faults.
Image - Do-it-yourself gazelle engine repair

In some cases, it is better not to make self-repair due to the fact that the use of special equipment is required.

Do-it-yourself Gazelle repairs are mainly carried out due to malfunctions of the car's chassis. In most cases, such a machine is used to transport goods, and the Gazelle Business can be used as a vehicle for passengers. Due to the fact that many motorists often overload the car, the suspension elements wear out and break much faster.

Repair of chassis on a Gazelle truck

spring bolts;
springs;
leaf springs and springs;
other bridge mountings.

Due to the breakdown of one of the listed parts, the performance of the car can significantly decrease: speed, smoothness, handling. If the Gazelle is used for transportation, it is recommended to carry out regular maintenance, check the chassis, and also carry out design upgrades to increase the operational capabilities of the machine.

Since the repair of most types of faults is described in the instructions, just remember which parts you need to check. To avoid frequent problems, it is recommended:

Less overloading the car. The instructions indicate the recommended weight that the Gazelle design can withstand. Of course, it can be exceeded, but in the future this will affect in the form of breakdowns, and these are unnecessary costs that can be avoided.
Carry out a technical inspection regularly, as it will prevent various troubles on the road.
Drive on the highest quality road surface.

Back to the table of contents

Most users of Gazelle and Gazelle Business car models claim that the axle and suspension of the car have a very strong structure and practically do not break even in the most severe conditions. In fact, this is not the case. The design is really very strong, despite many shortcomings, but it can withstand overload only by a miracle, which will be seen later, when the car "sags" under its own weight. Here are the consequences of overloading:

nuts and bolts on the bridge burst;
the spring and springs are deformed;
fastenings on compression springs are untwisted;
shock absorbers break.

All these breakdowns are easy to fix yourself using a minimal set of tools.

Gazelle truck with air suspension

If you use your Gazelle Business for cargo transportation, strengthen its springs with several additional sheets. In addition, replacing oil shock absorbers with more modern gas ones will come in handy.

Chassis Gazelle Next

Serving the Gazelle with your own hands is quite simple, here is a list of actions that are recommended to be performed regularly:

Every 10-15 thousand km it is necessary to carry out a full check of the car. If the transport is used in harsh conditions, it is recommended to check more often - once every 6-7 thousand km.
It is worth checking the quantity indicators daily: oil, fuel, coolant, technical fluids in the brake system and clutch drive.
Check the performance of the braking system before driving on the road, as well as the tire pressure.
The driver of the car does not have to perform this service on his own, you can visit the service station, where they will carry out a full diagnosis of the car for problems, pump up the wheels and carry out repairs, but you will have to pay for the services. The price for such a service will be about several thousand rubles, and in case of repair of the node - up to 10 thousand rubles. and even more.
You can independently change oil, fuel and other technical fluids, partially disassemble the unit, change some parts.

Inexperienced users are not recommended to completely disassemble the chassis and engine assemblies. Installation of additional electronic devices - stove, radio, GPS, board computer, etc. - leads to a load on the system. Make sure that the electronic resource of the car will be sufficient to maintain the performance of the battery and installed gadgets. Otherwise, the battery will often be discharged, as a result, the car will stop.

The old-school Gazelle engine rarely breaks down, but neatly.

Replacing the engine on a Gazelle car

But there are some engine problems that you can fix yourself. A good example is the service Gazelle 405. It often happens that the car simply stalls. Experts say the problem is the sheer amount of electronics in the system.

In most cases, the cause is an open ground contact. Check it out, and if it really is, then here is one method to solve the problem:

Cut the conductor a few centimeters below the oxidized contact.
Strip the wire.
Screw on the new contact, isolate it using any convenient method.
Screw the contact onto the stud. File the contact area with a file.

More complex manipulations with wiring, if you do not have the necessary knowledge and skills, are not recommended to be performed.

The simplest do-it-yourself Gazelle repair consists in various little things - to clean the filter, replace the liquid. Oddly enough, this also helps with fairly serious problems, for example, when the engine does not start.Clogging of various systems can lead to overheating of the engine, improper formation of the air-fuel mixture, and deterioration of fuel quality. When driving on dusty roads, frequent checking of the air filter is recommended.Here is a short list of the simplest steps to take to solve various engine problems:

The engine will not start in cold weather. Most likely, this is due to hypothermia of the system. Warming up the knot helps to cope with this inconvenience.

When the engine is turned on, pops are heard from the carburetor or exhaust system - check the filters in the fuel line and air duct, replace or clean them, check the details of the above units.

It is not recommended to disassemble the node without a special stand, as you are more likely to waste more time and get several additional problems than get rid of one problem.

In this video, the author, Travnikov Evgeny Alexandrovich, tells his viewers about the repair of the 406 engine.He divides the 406 engine repair video into several steps.

Stage 1 - Troubleshooting and disassembly. In this part, the author introduces us to the structure of the 406 engine, its components, corresponding defects (leakage from the phase sensor, moisture in the front oil seal). This repair of the ZMZ 406 engine, the video of which was presented by E.A. Travnikov, could have happened earlier, but thanks to the good car oil, its condition is simply excellent, you cannot say that this engine clocked more than 300 thousand km. The author also gives a vivid example of dismantling the engine, while talking about all the details, their specifics and the reasons for the breakdown. After removing the head, it turned out that the whole problem was in the gasket, or rather, in the fact that it was frayed and passed oil.

Eugene also tells his viewers about the most important structural element - about the drive of the secondary shaft, namely about its fastening features. Shows how the indicator can be used to determine the knocks in the crankshaft.

Stage 2 - Assembly of the block. On this cycle, the author talks about the fact that after some turning work, to increase the compression ratio, 2 mm were removed from the block surface, after which the surface was sanded. Shows how the crankshaft is installed, the cover with the oil seal is installed, how the connecting rods are checked for weight, how the connecting rods are weighed over the upper head, how the pistons are balanced.

Stage 3 - Cylinder head. The video shows us that an increase in the compression ratio of the piston protrudes 2 mm from the block (so that the piston does not meet with the head, a small groove is made). The author also showed how the gasket is installed and demonstrated the installation of the guides.

In general, this set of video tutorials helps a lot in automotive practice, because thanks to them we can independently find out the causes of engine breakdowns, and more importantly, eliminate them on our own.

Any engine wears out during operation, and this happens not only with internal elements, but also outside. This indicator is influenced by many factors that destroy the engine. So, let's consider the reasons why the ZMZ 402 engine needs repair, especially with regard to capital restoration:

The process of carrying out repairs, including overhaul, for the ZMZ 402 engine and its modifications, is similar to other power units of the series. All power units manufactured and manufactured by the Zavolzhsky plant are similar in design characteristics, and therefore repairs are quite easy. So, let's look at how to repair the ZMZ 402 engine with our own hands.

Repair of the ZMZ 402 engine begins with the dismantling of the power unit. The process is fairly straightforward, but four-handed is recommended. But, there is one difference, if the internal combustion engine is removed from the Volga, then this is one sequence of procedures. As for the 402 Gazelle engine, here the dismantling technology is slightly different. In order not to get confused, consider the classic process of removing a motor from a Volga car.

So, what sequence of operations needs to be performed by the motorist, what to remove the engine from the vehicle:

First, the battery is dismantled and its shelf is unscrewed.
Next, you need to remove the air filter and carburetor.
Disconnect the front pipe from the exhaust manifold.
We unscrew the spark plugs, remove the wires and the distributor.
We drain the engine oil.
Disconnect the fuel system.
Remove the fan impeller.
We dismantle the starter and generator, as well as the wiring associated with them.
Disconnect the clutch from the gearbox.
Dismantle the oil filter housing.
We remove the radiator and pipes of the cooling system.
We dismantle the intake and exhaust manifolds.

Further, when everything is disassembled, we completely remove the hood so that you can be unhindered, pull out the engine. We dismantle the power unit by hooking it onto a hoist or winch. Now, we install the motor on a special stand, if there is none, then on pallets and proceed to disassemble it. The motorist needs to disassemble his engine completely.

To do this, remove the parts in the following sequence: clutch, valve cover, oil pan, cylinder head, oil and water pumps, pistons, yoke, crankshaft. Now you can start the procedure for diagnosing the condition of the parts.

Diagnostics of engine parts begins with an inspection of the integrity of the cylinder block and crankshaft. If necessary, the body can be welded with special welding. If the block is very susceptible to destruction, then it should be replaced with a new one.

The next step in the diagnosis is cylinder measurement. The standard for ZMZ 402 is the size of 92 mm. But, if there is an elaboration on the walls, scratches or shells, then you will have to sharpen it to the next size. And if the measurement showed that the walls have already been repaired, then it is imperative to sharpen it to the next one, since the cylinders have a depletion and it must be eliminated.

Consider a table of the dimensions of repairs for the power unit 402 and its modifications:

Video guide to car body repair GAZEL. All repairs are done by hand.

Also watch the video on repairing the body of other cars.

We buy the necessary body parts for repair, in this case it is an arch, a tail and a side plate for a gas tank;

We cut off the old metal from the body;

We will weld on new linings (arch, tail, gas tank cover);

We prime, plaster and paint the body. The repair is over.

Are you a driver? And you chose a Gazelle car for the cargo transportation? But because of our roads, does your "iron friend" need body repair? You do not know how to repair the body Do-it-yourself gazelles? Then this video tutorial is for you! In it, we will show you step by step how to carry out repairs with your own hands, which will not be difficult.

Body damage can be of different "severity":

broken or rotten part of the leaf, etc.

To begin with, any, even micro-damage to the body does not paint the car, moreover, they can lead to negative consequences under the influence of the environment (for example, metal corrosion). You can watch this in the video on body repair. Gazelles with their hands. Therefore, in order to avoid expensive repair work, you should monitor the condition of your car on a daily basis.

we apply a repair insert;

cut off the damaged parts of the body below the outline by 1 centimeter;

then we make edges on the body with an edge bend;

then we try on a repair insert, and around its perimeter we beat holes with a hole punch every 2 centimeters;

we clean the edge on the body;

we apply a repair insert to our already edge, and scald along the holes;

then we clean the welding points;

we pass the primed internal joint seam with a special sealant;

putty outside, take out, primer;

It is important that when performing welding work, do not forget about eye protection, wear a special mask. Even an avid welder can get burned when performing such work.

Friends, do not forget to undergo periodic inspection, this will save not only your money, but also time.

To replace the window regulator at GAZelle Sobol, you will need as many as two screwdrivers - one regular and the second Phillips, and also a wrench with a diameter of 10 millimeters.First of all, open the latches on the door handle with a flat screwdriver, then use a 10-inch wrench to unscrew the two bolts that secure the handles to the door body itself.

Next, use a slotted screwdriver to unscrew the screw that secures the case to the inner handle of the lock. Next, to remove the plastic door trim, take a slotted screwdriver, pull out the fasteners and remove the noise insulation. The glass lifter mechanism on Sobol is always attached in 4 places: with three bolts - to the door, as well as two nuts and two bolts directly to the glass mount.

Unscrew all this with a key 10 mm in diameter. After disconnecting the mount from the glass and lifting the glass, which now does not interfere in any way, now unscrew the three bolts from the gearbox, remove the Gazelle glass lifter mechanism from the door itself. To repair the lift, you need to disassemble the gearbox of the glass lift itself.

Open the case, find a breakdown of low-quality plastic - a jumped off cable, jammed and caused increased friction on the plastic gears. Such a glass lifter cannot be repaired at all, therefore, replace it with a new original lifter.

Today, many drivers involved in cargo transportation choose Gazelles among all small lifting vehicles. Moreover, do-it-yourself repair is a reality and, by and large, is not difficult. The main thing in this matter is to have certain knowledge.

As you know, it is always easier to prevent a malfunction than to try to fix it later. This also applies to such an operation as the repair of the UAZ patriot and to any other vehicles. Moreover, car manufacturers quite clearly stipulate the recommended frequency of maintenance. In particular, for a Gazelle car, repair and maintenance should be carried out at the following intervals:

daily maintenance,

periodic technical inspection (every 10,000 km under normal operating conditions and every 6,000 - under extreme).

The following operations can be attributed to the daily technical inspection:

visual check of the levels of all working fluids, including: oil in the crankcase, fluid in the cooling system, fluids to the master cylinders of the brake system and the clutch release drive,

visual inspection of the tightness of the cooling, power supply and lubrication systems,

checking the health of the brake system,

checking the functionality of the parking brake system (performed by checking the movement of the brake lever),

the air pressure is checked on cold tires,

at the end of the trip, it is also necessary to clean the body, check the tightness of all cooling and other systems and check the integrity of the tires.

Periodic maintenance, like repairs, will require the implementation of some specific operations that can only be performed in a car service. For example, a small repair of a Gazelle with your own hands may well be performed, but if we are talking about an operation such as repairing an engine, then you cannot do without the involvement of specialists and appropriate test stands.

So, "heart surgery" of your "iron horse" may be needed in the following cases:

the inability to start the engine may be due to its hypothermia in winter. Also, the reason for the refusal to work can be a violation of the gasoline supply and the inconsistency of the combustible mixture (too "poor" mixture will respond with pops in the carburetor, and "rich" - in the muffler),

unstable engine operation can manifest itself as interruptions at low crankshaft speeds or interruptions in cylinder operation, as well as in deterioration of vehicle dynamics.

As already mentioned, engine repair, like generator repair, requires specific equipment and very thorough diagnostics. Small details can often be the cause of malfunctions.For example, a clogged fuel line or failure of the strainer will affect the operation of the entire engine as a whole. At the same time, engine repair without fail requires preliminary defect detection, as well as gearbox repair. It is best to perform such manipulations at a test stand, and disassembling the engine in a “garage” environment in order to determine what is out of order there, as a rule, leads not only to the loss of the driver's personal time, but also to an increase in subsequent costs.

The operations requiring professional intervention include body repairs. In most cases, Gazelle body repair involves restoring the integrity of some elements or paintwork. These operations include:

abrasive polishing of the body,

elimination of minor defects (scratches and chips),

partial replacement of body parts,

anti-corrosion treatment of units.

In this case, it is recommended to make repairs as soon as faults or defects are found, even if we are talking about small scratches. As you know, even a slight damage to the protective paint and varnish layer contributes to the formation of corrosion, which will subsequently force you to turn to welding, and this is many times more expensive.