Engine ZMZ 406 2.3 l.
Characteristics of the ZMZ-406 engine
| Production | ZMZ |
| Engine brand | ZMZ-406 |
| Years of release | 1997-2008 |
| Cylinder block material | cast iron |
| Supply system | injector / carburetor |
| Type of | inline |
| Number of cylinders | 4 |
| Valves per cylinder | 4 |
| Piston stroke, mm | 86 |
| Cylinder diameter, mm | 92 |
| Compression ratio | 9.3
8* |
| Engine displacement, cubic cm | 2286 |
| Engine power, hp / rpm | 100/4500* 110/4500** 145/5200 |
| Torque, Nm / rpm | 177/3500* 186/3500** 201/4000 |
| Fuel | 92 76* |
| Environmental standards | Euro 3 |
| Engine weight, kg | 185* 185** 187 |
| Fuel consumption, l / 100 km - town - track - mixed. |
13.5 — — |
| Oil consumption, gr. / 1000 km | up to 100 |
| Engine oil | 5W-30 5W-40 10W-30 10W-40 15W-40 20W-40 |
| How much oil is in the engine | 6 |
| When replacing pouring, l | 5.4 |
| Oil change is carried out, km | 7000 |
| Engine operating temperature, deg. | ~90 |
| Engine resource, thousand km - according to the plant - on practice |
150 300+ |
| Tuning - potential - without loss of resource |
600 + up to 200 |
| The engine was installed | GAZ 3102 GAZ 31029 GAZ 3110 GAZ 31105 GAZ Gazelle GAZ Sable |
* - for the ZMZ 4061.10 engine
** - for the ZMZ 4063.10 engine
Malfunctions and repair of the Volga / Gazelle ZMZ-406 engine
The ZMZ-406 engine is the successor to the classic ZMZ-402, a completely new engine (albeit made with an eye on the Saab B-234), in a new cast iron block, with an overhead camshaft, the latter now have two and, accordingly, a 16 valve engine. On the 406th, hydraulic lifters appeared and you are not in danger of fiddling with constant valve adjustment. The timing drive uses a chain that requires replacement every 100,000 km, in fact, it runs more than 200 thousand, and sometimes it does not reach 100, so every 50 thousand km you need to monitor the condition of the chain, dampers and hydraulic tensioners, tensioners, usually, very low quality.
Despite the fact that the engine is simple, without variable valve timing and other modern technologies, for GAZ, this is a great progress in relation to the 402 engine.
Engine modifications ZMZ 406
1. ZMZ 4061.10 - carburetor engine, SZh 8 for 76th gasoline. Used on Gazelles.
2. ZMZ 4062.10 - injection engine. The main modification is used on the Volga and Gazelles.
3. ZMZ 4063.10 - carburetor engine, SZh 9.3 for 92nd gasoline. Used on Gazelles.
Malfunctions of ZMZ 406 engines
1. Hydraulic tensioners of the timing chain. It tends to jam, as a result of which the absence of oscillations is not ensured, the noise of the chain occurs, followed by the destruction of the shoe, the jumping of the chain, and possibly even its destruction. In this case, the ZMZ-406 has an advantage, it does not bend the valve.
2. Overheating of ZMZ-406. A common problem, usually the thermostat and a clogged radiator are to blame, check the amount of coolant, if everything is in order, then look for air locks in the cooling system.
3. High oil consumption. Usually the case is in the oil scraper rings and valve seals. The second reason is a labyrinth oil deflector with rubber tubes for oil drainage, if there is a gap between the valve cover and the labyrinth plate, then the oil leaves. The cover is removed, coated with sealant and there are no problems.
4. Thrust dips, uneven XX, these are all dying ignition coils. On the ZMZ-406 this is not uncommon, change it and the motor will fly.
5. Knock in the engine. Usually, hydraulic lifters knock on the 406th and ask for a replacement, they go about 50,000 km. If not, then there are a lot of options, from piston pins to pistons, connecting rod bushings, etc., an autopsy will show.
6. Engine troit. See candles, coils, measure compression.
7. ZMZ 406 stalls. The point is, most often, in the BB wires, the crankshaft sensor or the IAC, check.
In addition, sensors are constantly buggy, electronics are of poor quality, there are problems with the gas pump, etc. Despite this, the ZMZ 406 is a giant step forward (compared to the ZMZ-402 of an outdated design), the engine has become more modern, the resource has not gone anywhere, and as before, with adequate maintenance, timely oil change and a calm driving style, it can exceed 300 thousand .km.
In 2000, on the basis of the ZMZ-406, the ZMZ-405 engine was developed, and later a 2.7-liter ZMZ-409 appeared, a separate one about it.
Volga / Gazelle engine tuning ZMZ-406
Forcing ZMZ 406
The first option for increasing engine power, by tradition, is atmospheric, which means we will install shafts. Let's start with the intake, install a cold air intake, a larger receiver, cut the cylinder head, modify the combustion chambers, increase the diameter of the channels, grind, install the appropriate, lightweight T-shaped valves, 21083 springs (for evil variants from BMW), shafts (for example, OKB Engine 38/38). It makes no sense to twist the standard tractor piston, so we buy forged pistons, light connecting rods, a lightweight crankshaft, we balance. Exhaust on 63 mm pipe, straight-through and we set it all up online. The output power is approximately up to 200 hp, and the character of the motor will receive a pronounced sporty touch.
ZMZ-406 Turbo. Compressor
If 200 hp for you childish fun and want real fire, then blowing is your way. In order for the motor to withstand high pressure normally, we will put a reinforced forged piston group under a low SG ~ 8, otherwise the configuration is similar to the atmospheric version. Garrett 28 turbine, manifold for it, piping, intercooler, 630cc injectors, 76mm exhaust, MAP + DTV, setting in January. At the output, we have about 300-350 hp.
You can change the nozzles to more efficient ones (from 800cc), put the Garrett 35 and blow until the engine collapses, so you can blow out 400 or more hp.
As for the compressor, everything is similar to turbocharging, but instead of a turbine, manifolds, pipes, an intercooler, we put a compressor (for example, an Eaton M90), set up and drive. The power of the compressor options is lower, but the motor is flawless and pulls from the bottom.
The 406 injector engine for the Volga car is presented in the form of an in-line four-cylinder engine with 16 valves. The injection is regulated by an electronic control system. Power units of this type are installed on GAZ 3302 and 3110 cars.
Later internal combustion engines of the ZMZ 4062 model are equipped with a distributed injection system.
Design features of the injector ZMZ 406 engine
The 406 injector engine has certain design features:
- The camshafts are located at the top of the cylinder head.
- Each cylinder contains four valves.
- Increased compression ratio of 9.3.
- Replacing the carburetor power system with a different, more advanced design.
The compression ratio is increased both through the use of spark plugs located in the central part of the combustion chamber, and through the use of an injection system of a fundamentally different type. Fuel combustion is the most complete. The usual carburetor power system is also changed here.
In Gazelle 406 engines, injectors of the new version, the cylinder blocks are made of durable cast iron instead of the usual aluminum. The design of the cylinder head (cylinder head) does not provide for insert liners, it is characterized by higher stiffness and stability of clearances.
The engineers provided for a noticeable reduction in the piston stroke, now it is equal to 86 mm. The weight parameter of pistons and pins has been reduced due to the use of more technologically advanced modern materials. Modern quality materials are also used in the manufacture of the crankshaft, connecting rods and other parts.
To drive the camshafts, an original chain design is used, equipped with automatic hydraulic tensioners. The new motor does not require constant adjustment of the required clearances.
The forced ZMZ 406 injector uses a higher quality lubricant, an improved design oil filter and additional cleaning elements.
With the help of a new power unit control system, the ignition system, fuel metering, and ignition angle adjustment have been improved.
Injection type design advantages
Thanks to the improvements in the engine design, there have been tangible changes in the characteristics of the updated power unit:
- Increased power.
- Increase in torque.
- Reduced fuel consumption.
- Improving exhaust gas toxicity indicators.
Technical characteristics of an injection internal combustion engine (ICE):
- The volume of the cylinders is 2.3 liters.
- The direction of rotation of the crankshaft is to the right.
- The maximum power that the ZMZ 406 injector engine is capable of developing is 110 horsepower.
- The brand of the consumed fuel is gasoline 92.
- Fuel is injected directly into the pipe.
- The lubrication system works on the principle of forced uniform spray of oil under pressure on the rubbing surfaces of working parts.
The motor is cooled forcibly using antifreeze or antifreeze coolant.
Which motor to choose - carburetor or injection
Many car owners are increasingly attracted by the injection version of the power unit instead of the usual carburetor model. Gazelle 406 injection engine is increasingly being installed on heavy vehicles.
The Zavolzhsky Automobile Building Plant equips such cars as the Volga, UAZ, Gazelle with more powerful injection engines. These brands of cars require an increase in power, a gasoline power unit of this type is capable of developing as much horsepower as is required for their stable operation.
Cons of a carburetor engine
Comparing the 406 carburetor engine with the injection analogue, one can be convinced of the noticeable superiority of the second in terms of power and performance. The main reason for the significant differences is the original power system. In a carbureted engine, fuel is fed into the cylinder as the rpm rises, resulting in lower power and acceleration values.
The carburetor engine is less economical due to the impossibility of precise adjustment of the gasoline supply. It is almost impossible to more accurately adjust the amount of fuel, which is reflected in the indicators of power and fuel consumption.
Despite the disadvantages described, many car owners love their carburetor engines. A car equipped with such a power unit is as reliable and durable as a proven horse can withstand the load.
Advantages and disadvantages of injection power units
ZMZ 406 engine injector noticeably surpasses the carburetor counterpart in reliability, efficiency and power. One of the main positive qualities of injectors is the absence of the need to make mandatory motor adjustments. The fuel system is not subject to clogging, there are no jets, and the exact amount of fuel is supplied directly to the cylinders.
The main disadvantage of injection-type engines is the inability to independently restore the operating mode. Judging by the numerous reviews, if the engine breaks down on the way, the driver will not be able to repair it with his own hands.
This is due to the fact that the functioning of all systems of injection-type power units is carried out under the full control of electronics. Failure of at least one electronic sensor will change the performance of the entire combustion engine.
In order to avoid unstable operation or stop of the injection engine, it is necessary to install only imported elements, carry out regular maintenance and thorough diagnostics of the car.
Description of the problems encountered
The power units of the ZMZ 406 are very susceptible to repair measures, many components and parts are being successfully restored. The following operations are most often performed:
- crankshaft grinding;
- boring of the block of cylinders.
Due to the fact that the cylinder head is made of cast iron, this part does not suffer from low-quality types of coolants. The main demand for high quality lies only in the engine oil. The internal department of the 406 injection power unit is very sensitive to the incorrect selection of the lubricant brand, and also requires a complete replacement of the engine oil on a regular basis at the specified time.
Numerous reviews of car owners indicate an increased consumption of lubricant on GAZ 406 injection-type engines.
Conclusion
The main and main advantages of the 406 power unit ZMZ include high efficiency (efficiency) and reliability. Due to the fact that any unit and internal part can be replaced with imported samples, it is possible to significantly extend the service life of the vehicle and increase its efficiency.
avtodvigateli.com
ZMZ 406 engine carburetor: characteristic
The ZMZ 406 engine, the carburetor replaced the 402 model and was originally intended in the development process for installation on a new family of GAZ-3105 representative cars. However, in connection with the closure of the project of a new executive class car, the target group of consumers was changed and the plant began to supply the engine to the produced cars of the GAZ family.
As the production of automotive equipment developed, the engine began to be installed on low-tonnage trucks of the Gazelle family and all-wheel drive vehicles produced by the Ulyanovsk Automobile Plant.
The engine was designed from scratch. For the basic prototype, the Swedish engine, the H series, was taken, which was installed on SAAB-9000 cars. The carburetor version has factory indexes ZMZ -4061.10 and ZMZ-4063.10
The resulting in-line petrol four borrowed double camshafts and an electronic ignition distribution system as a constructive solution. For 1993, it was a revolutionary decision for the Russian car industry. ZMZ was the first to use the DOHC design scheme for deliveries to Russian car factories. Although by 1997, the beginning of deliveries to car factories, the 406 engine already had an outdated design, comparing it with the same Saab.
The copying of technological solutions did not allow the actual parameters of the prototype to be removed from the engine. And instead of 150 hp and 210 Nm of thrust as in the prototype, the brainchild of the Zavolzhsky Motor Plant with a carburetor produced 100 hp. and 177 Nm with the same volume of 2.3 liters. The technical characteristics of the original were achieved only after additional refinement of the engine with the installation of an injection fuel injection system.
ICE ZMZ-406 carburetor was installed on the version of light trucks and vans manufactured by JSC "GAZ" until 2006. GAZ 3302. on which a dv 406 carburetor was installed, was perhaps the most common model due to its relative cheapness.
Also, a carburetor engine of this family was installed on passenger cars of the Volga family. This engine provided the lowest cost option for the car.
Electronic ignition system
The completely Russian development of the electronic filling is now practically unified and a different version of this electronic unit can be installed. It should be noted that the software must be built taking into account the technical characteristics of a particular engine.
A gazelle with an engine 4061.10 was designed for operation on 76 gasoline and the 406 engine had a reduced compression ratio, respectively, firmware was required to ensure stable engine operation on this fuel.
Electronic ignition units for power units are not interchangeable with other engine series. Those. block for 405 is not suitable for installation on a gazelle equipped with a 406 engine.
Fuel system
The engine had two versions, which allowed the use of 76 and 92 gasoline. Due to the transition to international environmental requirements, gasoline with an octane rating of 76 is no longer produced. For normal operation of the engine with index 4061.10, it must be modified.
Fuel is supplied by a diaphragm fuel pump driven by an intake camshaft.
Oil system
For engines of the 406 family, it is recommended to use mineral multigrade oil 10 (15) w40 or, according to API, no worse than SG class. Perhaps this recommendation is due to the fact that the engine plant produces oils under its own trademark.
In fact, it is worth focusing on the API class and choosing the oil viscosity in accordance with the climatic conditions of engine operation. The description of the API oil standard indirectly refers the development of this engine to 1989-1993.
Attention should be paid to the quality of the lubricating fluid itself, since stable characteristics ensure better and more durable operation of hydraulic lifters.
The capacity of the oil system of the power unit differs depending on the make of the vehicle. So for cars of the UAZ family, the design of the engine sump was changed.
Standard diseases 406
Overheat
The engine is very sensitive to overheating. On a long ride on a boiling engine, it drives the cylinder head. The problem with overheating is associated with poor pump performance and the condition of the cooling radiator. The materials used in the water pump have certain design tolerances that cannot guarantee the volumetric flow rate and pressure in the cooling system.
The design of the impeller allows for cavitation destruction of the blades, which reduces efficiency. In addition, there remains the question of the corrosion resistance of the pump shafts.
Inefficiency of the pump affects the condition of the internal channels of the radiator. With the external cleanliness of the surface, the channels narrow and the heat transfer decreases.
Another reason for overheating is poor performance of the thermostat. Incorrect setting of actuation or wedging of structural elements during operation.
The design features of the coolant channels and the lower location of the radiator can provoke the creation of locking air locks that impede the circulation of the liquid.
Oil consumption
During operation, an increased oil consumption of up to 1.5 liters per 1000 km of run is recorded. Oil consumption can occur without visible leakage. The problem is caused by poor quality seals, clogged labyrinth seals under the cylinder head cover, insufficient resistance of the O-rings. It is associated with poor-quality assembly and can be modified independently during operation.
Oil consumption is affected by the condition of the valve stem seals. Inspection and replacement as needed.
Loss of oil through block sweating is less common and cannot be corrected on its own, as the problem is related to the porosity of the cast iron used to cast the block.
Traction characteristics
Dips in idling performance and sudden loss of power while driving are caused by the failure of the ignition coil.
Ignition system
Malfunction of the engine "triplet" ignition system is caused by problems with the ECM software, spark plugs, ignition coil. Simultaneous failure of several system elements can be recorded.
Engine knocking
When using low-quality oil or insignificant overrun before changing the oil, the operation of the hydraulic lifters is disrupted. The knock is clearly audible even after the engine reaches normal temperature conditions.
Basically, all the malfunctions revealed during operation are due to poor quality components, as well as a low level of assembly culture at the plant, which was typical at the beginning of the production of the engine of this family.
Tuning 406
When tuning the 406 engine, the carburetor is replaced from the standard one to Sollers, although the technical specialists of the manufacturing plant indicate that such a replacement is not advisable, since the standard K-151D carburetor has consistent calibrations specifically for the 406 series engine.
A deeper alteration of the 4063.10 engine consists in changing the fuel supply system from a carburetor to an injection one. Such alteration is possible, but it is fraught with certain difficulties.
To increase air supply to the engine, replace the standard air filter housing and install a straight air filter. A deeper modernization of the air supply system consists in the removal of the intake manifold outside the engine compartment to reduce the temperature of the incoming air.
To improve heat transfer and reduce the temperature peak, oil radiators or radiators of the cooling system with an increased blowing area are used.
To increase power, it is possible to install a turbocharger, select camshafts, replace valves and CPG parts. But these improvements for light trucks are not justified from an economic point of view.
avtodvigateli.com
Engine 406 - description
The ZMZ 406 internal combustion engine is produced at the Zavolzhsky Motor Plant, which is the main supplier of components for the Gorky Automobile Plant (GAZ). Also, the ZMZ enterprise is engaged in the manufacture of a model 405 engine. These two motors have become the real pride of the Zavolzhsky plant. In terms of their design and technical data, they differ somewhat from each other. But still, almost every motorist knows their principle of operation.
What cars is this engine model installed on?
Most often, the 406th model engine was installed on the Volga model 31105, as well as on the well-known Gazelk cars. Moreover, since 2003, the Gorky Plant has completely updated the technical characteristics of all models of these trucks. From that moment on, the 402 engines were completely out of production and were no longer installed on any modern truck. They were replaced by two new units - ZMZ 406 and ZMZ 405.
406 engine - characteristics and description
This engine model went into mass production back in 1997. But, despite this, the GAZ 3302 "GAZelle" cars until 2003 were equipped with only 402 engines. The novelty ran on 92nd gasoline. The main detail that distinguishes it from other models is fuel injection, which was first developed by engineers at the Zavolzhsky plant. Over its long period of existence, the engine of the 406th model gained immense popularity and became one of the most common in Russia. It gained such popularity due to its reliable design and economical fuel consumption.
History of creation
During the operation of the 405th engine, significant drawbacks were noticeable: on hot summer days, the Volga and Gazelle simply overheated and boiled (probably everyone saw such a phenomenon when there was an empty plastic bottle under the hood of the GAZelle). This indicated flaws in the cooling system. Many drivers installed a three-piece radiator in place of the serial two-piece, but the engine sometimes made itself felt. The engineers of the Zavolzhsky Motor Plant understood that it could not go on like this, and began to develop a new injection engine ZMZ 406. It was not developed from scratch - its entire design resembled the 405th engine. But now all the shortcomings were taken into account and were not included in the new 406 engine (injector).
What are the changes in these two models?
So, the very first difference between the 406th motor is the presence of an injector. The carburetor had its drawbacks and was unreliable. The power of the novelty was 145 horsepower. The working volume is 2.4 liters. The unit has a significantly lower fuel consumption, and in winter it is very easy to start. Also, this motor is distinguished by its high reliability, which cannot be said about the 405. Actually, these are the main advantages, because of which many motorists choose the 406 engine.
Major overhaul
In about 200-300 thousand kilometers, this motor requires major overhaul. This procedure is much more expensive than repairing ZMZ 402 and 405 (about 30-40 thousand rubles). And all because of the complex design of the unit. Therefore, while operating "GAZelle", it should be remembered that after about 3-4 years it will require significant repair costs.
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ZMZ 406 carburetor - an overview of the most common problems
The ZMZ 406 carburetor began to be produced since 1996 and since then has managed to prove itself with good reliability and simplicity. With its reliability, it significantly surpasses the outdated ZMZ 402 engine on gas, which, after a breakdown, starts with difficulty.
Zmz 406 series engine
General characteristics
The ZMZ 406 engine is a carburetor, four-cylinder, and in-line engine with a microprocessor ignition system. Zmz 406 equipped with a carburetor has a power of 110 liters. with., and with an injector - 145 liters. with. In addition, injection modifications have different environmental standards. For example, ZMZ 4062.10 is class 0, and ZMZ 40621.10 is Euro - 2. An extra part in ZMZ 406 is an oil cooler, because the 6th engine does not heat up. In ZMZ 405, the oil cooler does not perform its functions, and the engine overheats in the heat and naturally does not start.
With a carburetor ZMZ 406 does not require so many costs when equipped with gas equipment. Moreover, this advantage applies to propane and methane, but with an increase in the class of environmental standards, the cost of gas equipment will also increase.
The cost of gasoline for the carburetor ZMZ 406 directly depends on the conditions and driving style, as well as the time of the year. The ignition system of the carburetor ZMZ 406 is considered quite reliable. The engine will be able to reach speeds of up to 500 thousand kilometers using high-quality oil and gasoline, as well as careful handling of the pedal.
Gazelle
The ZMZ 40524.10 model is a well-known gazelle carburetor. The brand of cars - "Gazelle" is one of the most popular and affordable trucks in Russia, which were originally intended for the transportation of not very large loads. Due to the huge number of such machines, we will consider several nuances of different gazelle systems. For example, a microprocessor ignition system, which is installed on the 406 model.
If the driver claims that his car emits some pops, jerks and loses its power. In this case, the power supply system, engine and ignition system must be checked. The carburetor was checked with a gas analyzer not during the operation of the 1st and 2nd chambers, cut-off, enrichment and during the idle run and did not find any violations. Then the engine is checked. When checking the compression, no problems were found, but the next time deviations from the norm were found. It was concluded that the jerks and pops that the driver did not like were due to the jump of the teeth of the upper chain.
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Carburetor zmz 406 series
What to do if gazelle power is lost?
From the very beginning, you need to check how the diagnostic circuit and the on-board diagnostics system function, because when the travel display mode is activated, a malfunction code of 12 should be obtained. To read the code, the 10th and 12th contacts of the diagnostic block must be closed. Using a diagnostic toaster, the parameters of the engine sensors are measured and then they are compared with the typical values of average engines. The most common reason for a decrease in vehicle power is a dirty tube that connects the intake manifold to the pressure sensor.
Gazelle ignition system
The microprocessor-based ignition system ignites the working fluid in the cylinders and sets the required ignition timing for all engine modes. The ignition system performs the function of regulating the operation of the forced idle economizer. Thanks to the ignition system, the operation of the engine becomes more economical, compliance with all emission standards is monitored, detonation is eliminated and the power of the vehicle is increased. If we compare the classic system with this one, then this ignition system is much more reliable and durable. Only the spark plugs can wear out here.
How Does Diagnostic Mode Work?
When the ignition system is turned on, the indicator lights up. At that very moment, the diagnostic system begins to work. If the entire system is in good working order, then the light stops glowing, and in the opposite case, it continues to burn. That is, an extinguished signaling device indicates that the ignition system is absolutely functional.
Carburetor zmz 406 series
Why does the 406 engine sometimes won't start during freezing?
The most common reasons a 406 won't start are:
- Poor quality oil;
- Insufficiently powerful battery, which does not allow the engine to start;
- Defective starter;
- Misaligned ignition system;
- Low-quality gasoline;
- Violation of the gasoline supply.
How do I adjust the carburetor?
- Disconnect the air damper drive cord;
- Remove the air filter and carburetor cover;
- Check the level of the float chamber, it should be below 3 centimeters from the edges;
- Remove the plug from the float rod;
- Make sure the sealing ring valve is tight;
- Install the top of the carburetor;
- Install the choke cable and air filter;
- Screw in the idle travel adjustment screw until the very end, unscrewing it five turns. Perform the same actions with the quality screw, but already unscrew it three turns;
- Start the power unit;
- Let it heat up to 90⁰;
- By turning the operating adjustment screw, select the crankshaft speed, about 700 rpm;
- Press the accelerator pedal and quickly release. If the motor stalls, increase the frequency;
- Go to a car dealership and adjust the CO and CH of the motor.
Those wishing to purchase a Gazelle are often interested in which modification to choose - with a ZMZ-406 or UMZ-4215 engine. The owners of "Gazelles" and the car service specialists who service these cars helped us to answer this question.
First, we will consider the design features of these engines. ZMZ-406 and UMZ-4215 are motors of different generations and with different "characters". 406th is a modern engine created in the early 90s by engineers of the Zavolzhsky Motor Plant. It uses a number of advanced technical solutions for the Russian automotive industry - four valves per cylinder, two overhead camshafts, hydraulic valve clearances, a hydraulic timing chain tensioner, a central location of spark plugs, a microprocessor-based ignition control system with feedback through a knock sensor. The ZMZ-4062.10 modification is equipped with a fuel injection system and is intended mainly for installation on the Volga model, while the ZMZ-4061.10 (for A-76 gasoline) and ZMZ-4063.10 (for A-92, A-95 gasoline) are carbureted and installed mainly for cars of the "Gazelle" family. It should be noted that ZMZ-4061.10 are practically not produced.
The Ulyanovsk motor 4218.10 (421.10 is its later improved modification) was developed in the early 90s, and its mass production was established in 1994. The design of this engine is obsolete, although it was created mainly for new models of UAZ off-road vehicles (3160, 3165). The designers were tasked with increasing the engine torque at low revs, which would ensure good cross-country ability of the machines. Since this characteristic directly depends on the surface area of the pistons, their diameter is 100 mm (because of this dimension, they are sometimes called "zilovsky"). The working volume was 2.89 liters (many rounded the number to three and called the motors "three-liter"). The new UMP motor delivers maximum torque at sufficiently low crankshaft speeds - from 2200 to 2500.
The study of the demand for Gazelle cars showed that many potential buyers would like to have a car with this new Ulyanovsk engine. UMZ-4218.10 is located in the engine compartment of the Gazelle somewhat differently than the 406th engine, therefore an additional radiator fan drive has been introduced, and several more changes have appeared. The modification of the UMP engine for the Gazelle received the marking 4215.10-30 (for the 92nd gasoline) and 4215.10-10 (for the 76th gasoline).
Advantages and disadvantages
In terms of reliability, the ZMZ and UMP engines are practically equal. Having purchased a car with a 406 engine, in some cases it is necessary to revise the electrical equipment, replacing the Russian sensors with Boshev ones, and improve the design of the hydraulic chain tensioner. This engine is also more demanding on the quality of service. For example, hydraulic lifters and hydraulic tensioners need high-quality semi-synthetic oil, and not "mineral water" of unknown origin, which was "fed" by 402 motors. In addition, it is advisable to use (especially during the engine break-in period) oil "superfilters" "Kolan" with an additional filter element on the bypass valve. This is recommended by the manufacturer himself. The fact is that large metal particles remaining in the channels of the block after its machining and assembly of the motor, as well as the products of running-in parts, can very quickly disable the hydraulic lifters and the hydraulic tensioner. An additional filter element just holds this debris, not allowing it to enter the lubrication system to the friction surfaces in the cold start mode of the engine. Unfortunately, such filters are quite rare in our sales, although they are produced in Ukraine - in Poltava.
The disadvantages of the UMP design include the insufficient balance of the crank mechanism. In order for the engine to work stably and smoothly at idle, it is necessary to enrich the fuel-air mixture (by adjusting the carburetor), and this leads to an increase in the toxicity of exhaust gases and an increase in fuel consumption. The Ulyanovsk motor, like the classic 402s, is much noisier than the 406 with its "light" soft sound. But UMP wins in terms of maintainability, since in design it is very close to the Volgovsk one, so it is easily operated and serviced in the outback, where there is no developed car service.
Possibilities
The "characters" of the motors are also different. The 406th is a high-revving engine providing good speed and dynamic characteristics of the Gazelle both in the city and on the highway. By its "behavior" such a car strongly resembles a passenger car. A low-speed UMP with maximum torque at low speeds is more suitable for those who like to overload the car and those who operate it in mountainous terrain or off-road. The high torque of the engine at the bottom in these situations will allow you to change gears less often and move more smoothly and confidently. Gazelles with Ulyanovsk power units are losing in terms of speed on flat roads and in acceleration dynamics. They are somewhat reminiscent of diesel engines (all because of the same maximum torque on the "bottom").
| Technical characteristics of motors ZMZ-406 and UMZ-4215 |
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The editors would like to thank the specialists of RosAvtoService LLC for their help in preparing the material.
The ZMZ 406 engine was developed to replace the 402 engine simultaneously with the design of the GAZ-3105 car for the government. However, these new Volgas were completed with them only in the last batch, which had to be urgently implemented in connection with the withdrawal of machines from production.
ICE ZMZ 406
The basis was taken ZMZ 402 (equipment) and the engine of the H series of the manufacturer SAAB (design solutions). As a result, with the same volume of 2.3 liters, the power drive provided 177 Nm of torque instead of 210 Nm of the prototype and 100 hp. with. power instead of the expected 150 hp, as in the Swedish ICE. The injection system, which was later replaced by the carburetor, was able to slightly correct the situation - 201 Nm and 145 hp. with., respectively.
Carburetor version ZMZ 4061.10
For the first time, several advanced technical solutions for that time were used in the engine of the ZMZ manufacturer:
- two intake and two exhaust valves per cylinder;
- electronic ignition and injection systems;
- DOCH gas distribution diagram with two overhead camshafts;
- hydraulic pushers instead of adjusting the thermal clearance of the valves with gaskets.
Valve pushers
After the changes made, the technical characteristics of the ZMZ 406 correspond to the values given in the table:
| Manufacturer | ZMZ |
| ICE brand | 406 |
| Production years | 1997 – 2008 |
| Volume | 2286 cm 3 (2.3 L) |
| Power | 73.55 kW (100 hp) |
| Torque torque | 177/201 Nm (at 4200 rpm) |
| The weight | 192 kg |
| Compression ratio | 9,3 |
| Nutrition | injector / carburetor |
| Motor type | inline gasoline |
| Ignition | commutator |
| Number of cylinders | 4 |
| Location of the first cylinder | TBE |
| Number of valves per cylinder | 4 |
| Cylinder head material | aluminum alloy |
| Intake manifold | duralumin |
| An exhaust manifold | cast iron |
| Camshaft | 2 pcs. DOCH schema |
| Cylinder block material | cast iron |
| Cylinder diameter | 92 mm |
| Pistons | original |
| Crankshaft | lightweight |
| Piston stroke | 86 mm |
| Fuel | AI-92 / A-76 |
| Environmental standards | Euro 3 / Euro 0 |
| Fuel consumption | highway - 8.3 l / 100 km combined cycle 11.5 l / 100 km city - 13.5 l / 100 km |
| Oil consumption | maximum 0.3 l / 1000 km |
| What oil to pour into the engine by viscosity | 5W30, 5W40, 10W30, 10W40 |
| Which oil is best for the engine by manufacturer | Liqui Moly, Lukoil, Rosneft |
| Oil for ZMZ 406 by composition | synthetics in winter, semi-synthetics in summer |
| Engine oil volume | 6.1 l |
| Working temperature | 90 ° |
| Internal combustion engine resource | declared 150,000 km real 200,000 km |
| Adjustment of valves | hydraulic pushers |
| Cooling system | forced, antifreeze |
| Coolant volume | 10 l |
| water pump | with plastic impeller |
| Candles for ZMZ 406 | domestic A14DVRM or A14DVR |
| Candle gap | 1.1 mm |
| Valve train chain | 70/90 with shoe or 72/92 with sprockets |
| The order of the cylinders | 1-3-4-2 |
| Air filter | Nitto, Knecht, Fram, WIX, Hengst |
| Oil filter | with non-return valve |
| Flywheel | 7 offset holes, 40mm bore |
| Flywheel Bolts | М12х1.25 mm, length 26 mm |
| Valve stem seals | Goetze, light intake, dark prom |
| Compression | from 13 bar, difference in adjacent cylinders max. 1 bar |
| Turnovers XX | 750 - 800 min -1 |
| Tightening force of threaded connections | candle - 31 - 38 Nm flywheel - 72 - 80 Nm clutch bolt - 19 - 30 Nm bearing cover - 98 - 108 Nm (main) and 67 - 74 (connecting rod) cylinder head - three stages 40 Nm, 127 - 142 Nm + 90 ° |
The factory manual contains a more accurate description of the parameters:
- ZMZ 4063.10 - carburetor, compression ratio 8 for operation on A-76 fuel, power 110 hp. sec., torque 186 Nm, weight 185 kg;
- ZMZ 4061.10 - carburetor, compression ratio 8 for A-76 gasoline, power 100 hp. sec., torque 177 Nm, weight 185 kg;
- ZMZ 4062.10 - injector, compression ratio 9.3 for AI-92 fuel, power 145 hp. sec., torque 201 Nm, weight 187 kg.
ZMZ 4063.10 
ZMZ 4062.10 injector
Officially, the ZMZ 406 engine became the third after 24D and 402 in the line of power drives of the Zavolzhsky plant. Got microprocessor ignition, DOCH timing with two-stage chain drive.
The developers still use the in-line engine with 4 cylinders, but there are two camshafts, they are located on top, inside the cylinder head. The compression ratio of the internal combustion engine was increased by the designers of the plant to 9.3 in the basic version 4062.10 due to the central location of the spark plug inside the combustion chamber.
Gas distribution mechanism design
Reliability is increased due to the cast-iron cylinder block without liners, reducing the piston stroke to 86 mm and the weight of the entire group of ShPG. Bolted connecting rods, crankshaft and piston rings are made of high strength materials, so less overhaul is required.
Timing chain tensioner
The chain tensioners are automatic, double acting - spring preload during hydraulic operation. The degree of oil purification is increased by installing a full-flow disposable filter. A separate V-belt drive is provided for attachments. ECU firmware corresponds to SOATE, ITELMA VS5.6, MIKAS 5.4 or 7.1 versions
List of ICE modifications
Initially, the engine was designed for injection, therefore version 4062.10 is considered basic. The need for carburetor modifications 4061.10 and 4063.10 arose later. They were installed on a Gazelle, therefore, while maintaining the volumes of the combustion chambers, it was necessary to reduce the owner's operating costs. For this, the management of ZMZ reduced the compression ratio in order to transfer the engines to the cheaper A-76 fuel.
The versions of the ZMZ 406 engine differ in combustion chambers
Reverse modernization was performed with motors 4061 and 4063:
- reduced power and torque;
- speed of XX steel 750 min -1 instead of 800 min -1;
- maximum torque is reached at 3500 rpm, not 4000.
All the rest of the attachments are located in the same places without changes. Some of the parts are interchangeable, with the exception of the cylinder head and piston.
Advantages and disadvantages
A negative feature of the power drive ZMZ 406 is the low quality of casting and unsuccessful technical solutions:
- high oil consumption due to the unfinished design of the rings;
- low resource of the timing belt of the drive due to the tensioner, collapsible block-star and bulky design as a whole.
Fuel consumption is high, but this is typical for most truck engines.
On the other hand, vibrations are reduced, the cylinder head does not unscrew during operation, the gasket does not need to be constantly changed, but the nuts must be pulled. The maintainability of all units is high, the design itself is reliable and simple. The user is relieved of the need to adjust the valve clearances every 20,000 mileage.
Intake manifold injector
List of car models in which it was installed
Since the ZMZ 406 engine has three versions, each of them was used on specific models of the auto manufacturer GAZ:
- ZMZ 4062.10 - GAZ 31054 of the Lux configuration; GAZ 3102 (1996 - 2008);
- ZMZ 4061.10 - GAZ 3302, 33023, 2705, 3221;
- ZMZ 4063.10 - GAZ 3302, 33023, 2705, 3221, 32213, 322132, 32214, SemAR 3234, Ruta, Bogdan and Dolphin.
GAZ Gazelle Farmer
In the first case, the characteristics of the engine were suitable for the urban cycle of the representative cars of officials and government. Carburetor modifications reduced the operating budget of Gazelle vans, utility vehicles and trucks.
Service regulations ZMZ 406 2.3 l / 100 l. with.
According to the manufacturer's requirements, the ZMZ 406 engine is serviced in the following order:
- inspection of the timing chain after 30,000 mileage, replacement after 100,000 km;
- oil and filter change after 10,000 km;
- replacing the coolant approximately every two years or 30,000 mileage;
- battery recharging every fall, replacement after 50,000 km;
- spark plugs last for 60,000 mileage;
- the fuel filter becomes unusable after 30,000 km, the air filter - 20,000 km;
- ignition coils fail after 50,000 mileage.
Repair of ZMZ 406
The manufacturer recommends using high-quality lubricant for the engines so that the hydraulic lifters and the oil pump work properly. Initially, the cooling system has weak points - a radiator and a thermostat. All attachments are highly durable, with the exception of the pump, the polymer rotor of which serves about 30,000 km. Due to the large weight of the motor with your own hands, it is very difficult to overhaul in the garage without a telpher.
Overview of faults and how to repair them
Due to the design features, the ZMZ 406 motor bends the valve only when the chain is skipping. Moreover, they are damaged against each other (intake and exhaust while lifting), and not on the pistons. If the circuit is broken, such a nuisance will not happen.
Since the ICE device was partially copied from the SAAB, and the design of the ZMZ 402 was partially preserved, it is characterized by malfunctions:
| High speed XX | 1) breakage of sensors 2) there is no controller contact XX 3) crankcase ventilation hoses are torn |
1) replacement of sensors 2) restoration of contact 3) replacement of hoses |
| Cylinder failure | 1) ECU malfunction 2) failure of the coil 3) breakdown of the tip of the candle 4) breakage of the nozzle |
1) replacement of the control unit 2) coil repair 3) tip replacement 4) repair / replacement of the nozzle |
| Unstable operation of the internal combustion engine | 1) air leaks 2) water in the fuel tank |
1) restoration of tightness, replacement of gaskets 2) draining gasoline, drying the tank |
| Motor does not start | 1) failure of the ignition system 2) the fuel supply is interrupted |
1) replacement of the coil, contact 2) replacement of the filter, reduction valve, phase adjustment, replacement of the fuel pump |
Due to the large diameter of the pistons, the block and cylinder head are sensitive to overheating, therefore, the level of working fluids should be monitored regularly (oils and antifreeze).
Engine tuning options
Initially, the ZMZ 406 engine allows you to increase power on its own to 200 - 250 hp. with. For this, mechanical tuning is used:
- installation of a zero resistance filter;
- decrease in air temperature in the intake tract;
- replacement of the standard K-16D carburetor with Solex (adjustment with quality / quantity screws is required).
Tuning ZMZ 406
For minibuses and Gazelle trucks, tuning with a turbocharger is ineffective, since the service life of the DS decreases and fuel consumption increases sharply.
Thus, the injection modification ZMZ 4062.10 and the carburetor versions 4061.10, 4063.10 are developed on the basis of the Swedish H series engine for trucks and executive cars. Tuning is allowed, first of all, to increase the torque.
Four-cylinder in-line engine, equipped with an integrated microprocessor
fuel injection and ignition control system (KMSUD).
Engine type mod. 4062 on the left side:
1 - drain plug;
2 - oil sump;
3 - exhaust manifold;
4 - engine support bracket;
5 - valve for draining the coolant;
6 - water pump;
7 - coolant overheat lamp sensor
liquids;
8 - the sensor of the gauge of temperature of the cooling
liquids;
9 - tempera sensor;
10 - thermostat;
11 - emergency lamp sensor
oil pressure;
12 - pressure gauge sensor
oils;
13 - crankcase ventilation hose;
14 - oil level indicator (dipstick);
15 - ignition coil;
16 - phase sensor;
17 - heat-insulating screen
The cylinder block is cast from gray iron. There are channels between the cylinders for
coolant. The cylinders are designed without insert sleeves. At the bottom of the block
there are five bearings of the crankshaft main bearings. Indigenous caps
The bearings are made of ductile iron and are attached to the block with two bolts. Lids
bearings are bored with the block, so they cannot be swapped.
On all covers, except for the third bearing cover, their serial numbers are stamped.
The cover of the third bearing together with the block is machined at the ends for installation
thrust bearing half washers. The chain cover is bolted to the ends of the block and
stuffing box with crankshaft cuffs. An oil sump is attached to the bottom of the block.
On top of the block is a cylinder head, cast from aluminum
alloy. It has intake and exhaust valves. For each cylinder
installed four valves, two inlet and two outlet. Inlet valves
located on the right side of the head, and the outlet on the left. Valve drive
is carried out by two camshafts through hydraulic tappets.
The use of hydraulic pushers eliminates the need to adjust the clearances in the drive
valves, as they automatically compensate for the gap between the cams
camshafts and valve stems. Outside on the body of the hydraulic pusher
there is a groove and a hole for supplying oil inside the hydraulic pusher from oil
highways.
Engine type mod. 4062 on the right side:
1 - synchronization disk;
2 - sensor of rotation frequency and synchronization;
3 - oil filter;
4 - starter;
5 - knock sensor;
6 - pipe for draining the coolant;
7 - air temperature sensor;
8 - inlet pipe;
9 - receiver;
10 - ignition coil;
11 - idle speed regulator;
12 - throttle;
13 - hydraulic chain tensioner;
14 - generator
The hydraulic pusher has a steel body, inside which a guide is welded
sleeve. An expansion joint with a piston is installed in the sleeve. The compensator is held in
sleeve with a retaining ring. An expansion joint is installed between the expansion joint and the piston.
spring. The piston rests against the bottom of the hydraulic pusher housing. Simultaneously
the spring presses the ball check valve body. When the cam
the camshaft does not press on the hydraulic pusher, the spring presses through
the piston the body of the hydraulic pusher to the cylindrical part of the camshaft cam
shaft, and the compensator - to the valve stem, while choosing the clearances in the drive
valves. The ball valve is open in this position and oil flows into the
hydraulic pusher. As soon as the camshaft cam rotates and presses on
pusher body, the body will drop down and the ball valve will close. Butter,
located between the piston and the compensator begins to work as a solid.
The hydraulic tappet moves downward under the action of the camshaft cam and opens the valve.
When the cam, turning, stops pressing on the body of the hydraulic pusher, it is under
the action of the spring moves upward, opening the ball valve, and the entire cycle
repeats again.
Cross section of the engine mod. 4062
1 - oil sump;
2 - oil pump receiver;
3 - oil pump;
4 - oil pump drive;
5 - gear wheel of the intermediate shaft;
6 - cylinder block;
7 - inlet pipe;
8 - receiver;
9 - intake camshaft
valves;
10 - inlet valve;
11 - valve cover;
12 - exhaust camshaft
valves;
13 - oil level indicator;
14 - hydraulic valve pusher;
15 - external valve spring;
16 - valve guide sleeve;
17 - exhaust valve;
18 - cylinder head;
19 - exhaust manifold;
20 - piston;
21 - piston pin;
22 - connecting rod;
23 - crankshaft;
24 - connecting rod cover;
25 - main bearing cover;
26 - drain plug;
27 - pusher body;
28 - guide sleeve;
29 - compensator body;
30 - retaining ring;
31 - compensator piston;
32 - ball valve;
33 - ball valve spring;
34 - ball valve body;
35 - expanding spring
Seats and guide bushings are installed in the block head with high interference
valves. Combustion chambers are made in the lower part of the block head, in the upper part -
the camshaft supports are located. The supports are equipped with aluminum
cover. The front cover is common to the inlet and outlet supports.
camshafts. This cover contains plastic stop
flanges that fit into the grooves on the camshaft journals. Lids
are bored together with the block head, so they cannot be swapped. On
all covers, except for the front one, have serial numbers stamped.
Camshaft cover installation diagram
The camshafts are cast iron. Intake and exhaust cam profiles
the shafts are the same. The cams are offset by 1.0 mm relative to the axis of the hydraulic pushers, which
makes them rotate when the engine is running. This reduces surface wear
hydraulic pusher and makes it uniform. The top of the block is closed with a lid on top,
cast from aluminum alloy. The pistons are also cast from an aluminum alloy. On
the bottom of the piston has four valve recesses, which prevent
strokes of the piston on the valves in case of a violation of the valve timing. For the correct
installation of the piston into the cylinder on the side wall near the boss under the piston pin is cast
inscription: "Before". The piston is installed in the cylinder so that this inscription is
facing the front of the engine.
Each piston has two compression rings and one oil scraper ring.
Compression rings are cast iron. Barrel-shaped work surface of the upper
the ring is covered with a layer of porous chromium, which improves the running-in of the ring. Working
the surface of the lower ring is coated with a layer of tin. On the inner surface of the bottom
the ring has a groove. The ring must be installed on the piston with this groove.
up to the bottom of the piston. The oil scraper ring consists of three elements: two
steel discs and expander. The piston is attached to the connecting rod using a piston
"floating type" finger, i. e. the pin is not secured in either the piston or the connecting rod. From
the movement of the pin is held by two snap rings, which
installed in the grooves of the piston bosses. Forged steel connecting rods, with a rod
I-section. A bronze bushing is pressed into the upper head of the connecting rod.
The lower head of the connecting rod with a cover that is fastened with two bolts. Connecting rod nuts
the bolts have a self-locking thread and therefore do not additionally lock.
The connecting rod caps are processed together with the connecting rod, and therefore they cannot
rearrange from one connecting rod to another. Numbers are stamped on connecting rods and connecting rod caps
cylinders. For cooling the piston crown with oil in the connecting rod and upper head
holes are made. The mass of pistons assembled with connecting rods must not differ
more than 10g for different cylinders. The lower head of the connecting rod is installed
thin-walled connecting rod bearings. The crankshaft is cast from ductile iron.
The shaft has eight counterweights. It is held against axial movement by persistent
half washers installed on the middle neck. To the rear end of the crankshaft
flywheel attached. A spacer sleeve and bearing are inserted into the flywheel bore
input shaft of the gearbox.
Cylinder numbers are stamped on the connecting rods and connecting rod caps. For cooling the bottom
piston with oil in the connecting rod and the upper head holes are made. Weight
pistons assembled with connecting rods should not differ by more than 10 g for different
cylinders. Thin-walled connecting rods are installed in the lower head of the connecting rod
liners. The crankshaft is cast from ductile iron. The shaft has eight
counterweights. It is kept from axial movement by persistent half washers,
installed on the middle neck. Attached to the rear end of the crankshaft
flywheel. A spacer sleeve and a primary bearing are inserted into the flywheel hole.
gearbox shaft.
