A car for people who do not like to be constrained by the road surface and at the same time prefer the comfort of movement. However, no matter how the designers strive to create a car that is quite comfortable and reliable as foreign analogues of SUVs, the UAZ Patriot cars still have a lot of significant drawbacks. One of which is a weak engine.
Specifications ZMZ-40911.10
| Number of cylinders | 4 |
| Working volume, l | 2,693 |
| Compression ratio | 9 |
| Maximum power (gross) at a crankshaft speed of -1, kW (hp) | 92 (125) 4250 ± 100 |
| Maximum torque (gross) at crankshaft rotation speed, Nm (kgcm) | 219.5 (22.4) 3000 ± 200 |
| Minimum specific fuel consumption g / kW (g / hph) | 279 (205) |
| Cylinder diameter and piston stroke, mm | 95.5x94 |
| Weight, kg | 190 |
| engine's type | Engine internal combustion, with positive ignition, external mixture formation and fuel injection into the intake ports of the cylinder head |
| Fuel | Gasoline Regular Euro - 92 |
A manifold with a turbine installed on the ZMZ 409 UAZ Patriot engine
Until recently, the turbo system for UAZ cars with a ZMZ 409 engine (Patriot, Pickup, Hunter) existed in the form of experimental design samples, the number of which numbered several dozen. They were not intended for free sale and were installed by service workers. This situation was partly due to less interest from potential buyers, as well as objective difficulties in choosing a turbocharger that is acceptable not only in terms of technical specifications and design, but also in terms of cost. The fact is that for a long time foreign engine builders have not produced gasoline turbo engines that are in any way comparable with the Zavolzhsky unit in terms of displacement and gluttony. Therefore, find an inexpensive serial gas turbine the required standard size was not easy. Several candidates auditioned for this role, including the GT-17 and several Mitsubishi turbine (MHI) models. Some raised the torque well at the "bottom", but limited it "at the top", while others, on the contrary, were included in the work with a long delay. In the end, the best option was found. It turned out to be a turbine Garrett TB-25- the model, to put it mildly, is not new, but the turbine fully meets all the requirements of the developers. From the point of view of ideology and design, the UAZ pressurization system is identical to that mounted on the Chevy. There are some differences in performance. In particular, the docking of the turbine with the exhaust manifold was solved differently. If a cast adapter unit is used for this in the VAZ-2123 engine, then in the ZMZ-409 engine the standard exhaust manifold is changed to a manifold diesel engine ZMZ-514. It is significantly more compact and has a standard 4-stud docking flange. Small problems arise due to the fact that cars arriving for turbo tuning are equipped with motors different modifications... They have a different crankcase ventilation system, idle move, throttle assembly, etc. All this complicates the task of creating a universal turbo kit - most likely, it will also be produced in several versions. The start of mass production of turbo kits for free sale is a matter of the very near future. In the meantime, everyone who wants to "charge" their personal or client UAZ, make it more responsive and comfortable in driving, can contact the company "Diaz-Turbo". Everything you need for the Patriots turbo tuning is there, and the service specialists will help you install and configure the turbocharging system.
Has anyone installed such a KIT for himself?
Factory-fitted UAZ Patriot is equipped with standard engine ZMZ 409. Its essential difference from earlier versions of UAZ engines is the injection type of fuel supply to the engine. This is a gasoline engine with a volume of 2.7 liters and a maximum power of which reaches 128 hp. However, many motorists believe that such an engine is weak for their UAZ Patriot car and therefore they tune it in every possible way. The most common type of tuning is the replacement of the standard ZMZ 409, with engines from other cars, mainly foreign SUVs and, moreover, diesel ones. However, such tuning is not cheap, but if we compare the cost of a foreign SUV, even a used one, and the cost of purchasing a UAZ Patriot and replacing an engine, the difference is significant (naturally towards the UAZ Patriot).
Tuning engine ZMZ 409 for UAZ Patriot. The second option for engine tuning is engine chip tuning. Since on the ZMZ 409 engine, an engine control system with a MIKAS 7.2 or MIKAS 11 control unit is designed. Modern technologies allow you to change the system settings in the most optimal way for your car's operation. This tuning allows you to reduce fuel consumption and increase technical parameters. In addition to chip tuning, you can additionally install a turbo compressor. By installing a turbocharger, you will get a significant boost in engine power. Installing such a unit will allow you to develop engine power up to 170 hp and increase the maximum torque to 290 Nm. In general, the engine power will increase by up to 30%. Such an engine will be most suitable for off-road driving and in difficult conditions. But besides this, one should not forget the precautions when operating an engine of even a ZMZ 409 or any other when operating in difficult conditions. Therefore, specialists who prepare cars of this class for off-road conditions recommend that, in parallel with tuning, work related to the removal of breathers in air filter and air intakes to a higher level. Such tuning will allow you to wade water obstacles without any problems. Similar operations can be performed when tuning the UAZ Hunter engine.
Turbocharger for UAZ Patriot
For a full modernization of the UAZ Patriot, it is best the engine will fit ZMZ 409. However, the installation of a turbine is not limited to everything. To improve performance and maintain the performance of the power unit, additional modernization should be carried out. So, when installing a turbine on a UAZ Patriot, you will additionally need to do the following:
First of all, we look at the pistons. If the turbocharger on the UAZ gives out 0.8 - 1, then you can leave your own pistons, but if the pressure exceeds 1, then MAMI forged pistons, which are made to order, are best suited (however, I found ready-made ones in one of the online stores) ... If you want to get a big "boost", it is best to mount an additional insert between the crankcase and the block to strengthen the engine block. As for the camshafts, in principle, you can leave the standard ones, but you can put "wide" ones (here it all depends on your goals and financial capabilities). The crankshaft on the UAZ Patriot does not require tuning, unless the time has come to repair it. But what will have to be changed for sure is the inserts: instead of the "native" ones, it is recommended to put the connecting rod and main bearings of Turbo ZMZ. Turbocharger for UAZ Patriot Turbocharger for UAZ Patriot
As for the installation of the collectors, it is recommended to have an exhaust EURO 2. But the standard intake manifold should be slightly modernized, eliminating all internal drops and installing an additional filter zero resistance and an intercooler. In the block, additional oil nozzles should be installed (we need them to cool the bottom of the pistons).
| 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 being carried out, km | 7000 |
| Engine operating temperature, deg. | ~90 |
| Engine resource, thousand km - according to the plant - on practice |
150 200+ |
| Tuning - potential - without loss of resource |
600+ up to 200 |
| The engine was installed | Volga 3102 Volga 31029 Volga 3110 Volga 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. Modifications of the ZMZ 406 engine: 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.
З 4063.10 - carburetor engine, СЖ 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 consumption oils. Usually the point is 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. Knocking in the engine. Usually, hydraulic lifters knock on the 406th and ask for a replacement, they go about 50,000 km. If not they, then there are a lot of options, from piston fingers to pistons, connecting rod bearings etc., an autopsy will reveal. 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, and in general, the poor build quality characteristic of Russian engines did not bypass the 406 engine either.
Despite this, the ZMZ 406 is a giant step forward compared to the ZMZ-402, the design of the mid-50s, 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 the 2.7-liter ZMZ-409 appeared.
Tuning the Volga / Gazelle ZMZ-406 engine (power increase)
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 a 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. 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. So that the motor endures normally high pressure, we will supply a reinforced forged piston group under a low SD ~ 8, otherwise the configuration is similar to the atmospheric version.
rbina Garrett 28, manifold for it, piping, intercooler, 630cc injectors, 76mm exhaust, DBP + 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, Eaton M90), set up and drive. The power of the compressor options is lower, but the motor is flawless and pulls from the bottom.
Increase in power ZMZ 406
A very exciting topic for many about what can be done with the ZMZ 406 engine so that the car will go as it should. For several years now I have been studying the possibilities and options for improving these motors, the pros and cons of various solutions. Finally I got myself together and decided to describe my experience in this article. I propose to start the topic of finalizing the motor from the very beginning, i.e. from the intake system. Inlet The configuration of the intake system is one of important points influencing ICE characteristics... Just like at prom, during intake system wave processes occur. The intake system on the atmospheric internal combustion engine ZMZ 406 is resonant and tuned to a certain speed range. In the factory version, the system has conflicting characteristics.
On the one hand, we have a rather short intake tract, which indicates a high-speed setting, on the other, a small cross-section of the intake holes on the filter housing. Note that the filter element itself is installed very efficiently and replacing it with a "zero resistance" filter is not a good idea, because such a filter requires regular maintenance(impregnation) and by default it filters worse. In order to improve the filling of the cylinders by high revs, I would recommend getting rid of the regular air filter housing (pan). But then we will get another not very good effect - the filter will already take air mainly from under the hood, where it is much hotter than outside. An increase in inlet air temperature decreases filling, i.e. power and moment. To solve this problem, it is proposed to install a "cold intake" system. This idea is not revolutionary and is well known. Under the hood, where the air filter is located, a closed volume is organized, air into which only from the outside enters. This is done by installing a partition. This option for improving the intake system is very popular on American cars. Of course, you can not fence off anything under the hood, but simply remove the air intake with a filter under the bumper, but then there is a danger of getting a water hammer when forcing puddles. And also the resonance characteristic of the intake will change. Tests have shown that the resonant frequency shifts down the rpm as the intake tract is lengthened.
the tire will ride a little better on the bottom, but as a result, the number of horses will decrease, because power = torque * revolutions. Release Most the best option in terms of price-result is the installation of a "cold intake" system together with an exhaust system from Euro2 / 3 engines. For those who want to get even more power, it is recommended to install a direct-flow exhaust system, it is more efficient in terms of power, but alas, it is quite noisy. If the question is not about the price, then it is possible to choose a compromise option from well-known world-class manufacturers. Further up the ladder of improvements (and of course costs) is the finalization of the cylinder head. Refinement of any cylinder head comes down to grinding the channels, smoothing out all sharp edges in the combustion chamber (and on the piston crown). For ZMZ 406 engines, it is also recommended to install a cylinder head gasket from a motor 405.22 euro3. It is all-metal (more reliable) and thinner, which will result in an increase in the compression ratio to 10. As you know, an increase in the compression ratio is one of the main ways to increase the efficiency of the internal combustion engine (increase efficiency, power - whoever likes what better). Camshafts The next step is to install high-lift camshafts. If the motor is planned to be operated in the city every day, then I would recommend opting for a pair of shafts 30/34 from the Engine okb. Technical specifications shafts 30/30 Extremely "low" version - provides the greatest increase in torque at low and medium speeds 30/34 The universal version - increases the torque evenly over the entire operating range.
4/38 "Horse" variant - increases torque at medium and high revs. 38/42 Provides the largest increase in torque at high revs. Other options It is also possible to install a crankshaft with a long crank stroke (from ZMZ 409, 94mm stroke instead of 86mm), which will increase the working volume to 2.5 liters, and as you know, the moment is directly proportional to the displacement. But besides the crankshaft, you will have to order other pistons with a finger shifted by 4mm so that the piston does not go out of the plane of the block and does not fight against the cylinder head. A good option for an atmospheric internal combustion engine is the use of pistons with thin rings, thin rings reduce dynamic friction losses and increase the overall efficiency of the engine, this is especially true for revving engines. You can also talk about the relief of pistons, connecting rods, crankshaft, flywheel ... but my personal opinion is that relief is not relevant for an engine operating in the range of up to 7000 rpm. Good weight distribution and balancing of moving parts is sufficient. The downsizing of the flywheel, which many people love so much, gives the motor a jittery color. It spins up faster, but also slows down faster, which is sometimes inconvenient, especially in the city. Engine management system Naturally, after any modifications to the internal combustion engine, you need to reconfigure the control system. This is perfectly handled by the M7Sport software, which was originally created to control the modified ZMZ motors. The main feature of this software is to work with an absolute pressure sensor instead of a mass air flow sensor.
also the ability to automatically calibrate all the necessary settings for a specific engine using the MOLT program, which allows you to achieve maximum output from each specific engine. Cross section of the ZMZ 406 engine on the Volga GAZ 31105 car: 1 - oil pan; 2 - oil intake; 3 - oil pump; 4 - oil pump drive roller; 5 - crankshaft; 6 - connecting rod; 7, 9 - driven and driving gears of the oil pump drive; 8 - oil pump drive cover; 10 - piston pin; 11 - piston; 12 - cylinder head gasket; 13 - inlet valve; 14 - inlet pipeline with a receiver; 15 - cylinder head; 16 - intake camshaft; 17 - hydraulic pusher; 18 - exhaust camshaft; 19 - cylinder head cover; 20 - oil level indicator; 21 - exhaust manifold; 22 - outlet valve; 23 - cylinder block; 24 - drain plug
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"ZMZ-406 Turbo": characteristics
Below are the parameters of the motor in question:
- Years of release - 1997-2008.
- The feed part is an injector / carburetor.
- The arrangement of the cylinders is in-line type.
- The number of cylinders and valves on each element is 4/4.
- Piston movement - 86 mm.
- Compression - 9.3.
- The volume of the "engine" is 2286 cubic meters. cm.
- The power indicator is 145 horsepower at 5200 rpm.
- The environmental standard is Euro-3.
- Weight - 187 kg.
- Fuel consumption in mixed mode is 13.5 liters per 100 km.
- The rated working life of the unit is 150 thousand kilometers.
- Installation - "Volga" 3102/31029/3110, (Gazelle, Sable).
Modifications
Several models of the ZMZ-406 Turbo engine were put into operation:
- Carburetor modification 406. 1. 10. Used on Gazelles, consumes AI-76 gasoline.
- Version 406.2.10. Injection motor, installed on "Gazelles" and "Volga".
- Model 406. 3. 10. Applied on "Gazelles" (AI-92).
Major malfunctions
The ZMZ-406 Turbo engine is most often subject to the following malfunctions:
- The hydraulic timing chain tensioners are susceptible to seizure. In this regard, there is extraneous noise, the absence of vibrations, further deformation of the shoe, up to the destruction of the entire chain. In this regard, the advantage of the engine under consideration is that the valves do not bend on it.
- Overheat power plant... This problem is also not uncommon. As a rule, such a breakdown occurs due to a clogged radiator or a failure of the thermostat. Initially, it is recommended to check the coolant level and the presence of air congestion in system.
- Increased oil consumption. Most often, the ZMZ-406 Turbo KIT engine experiences this problem due to wear of the oil seals and oil scraper valves on the valves. Also, a malfunction sometimes occurs due to the fact that a gap forms between the plate and the valve cover, through which oil leaks. To fix the problem, it is enough to remove the cover and treat the surface with a sealant.
Other problems
Among other frequently occurring malfunctions of the ZMZ-406 Turbo engine, the following can be noted:
- Traction dips are often observed due to failure of the ignition coils. After replacing these elements, the performance of the motor is restored instantly.
- Knock in the power unit. This problem occurs due to wear on the hydraulic expansion joints. According to the manufacturer, the service life of these parts is calculated for at least 50 thousand kilometers.
- Worn piston pins, pistons and connecting rod bushings, which also leads to the occurrence of extraneous sounds in the motor.
- The power unit is troit. In this case, you should check the candles, coils and compression.
- The fading of the power unit is observed. Most often, "ZMZ-406 Turbo" stalls due to a malfunction of the wires, crankshaft sensor or IAC.
In addition, failures in the operation of the ZMZ-406 Turbo clutch and the fuel pump have been repeatedly observed. In general, the causes of problems are typical for all domestic motors, including poor build quality. Nevertheless, the 406th model is much more efficient and practical than its predecessor under the number 402. For reference: on the basis of the 406th "ZMZ", motors of the 405th and 409th series, with a volume of 2.7 liters, were developed.
Forcing
One of the options for increasing the power of the unit is the atmospheric method with the installation of additional shafts. At the inlet, a cold air intake is mounted, a receiver with an increased diameter. Then the cylinder head is sawn, the combustion compartments are refined, the size of the channels is increased. At the next stage of the improvement of the ZMZ-406 Turbo engine, lightweight T-valves, type 21083 springs and new shafts, for example, from OKB 38/38, are installed.
It makes no sense to use a standard tractor piston group. New forged pistons and a lightweight crankshaft are acquired. Balancing the node. Adjustable straight-through exhaust on a pipe with a diameter of 63 mm. As a result, the power will be about 200 horsepower, and the characteristics of the power plant will have a pronounced sporty configuration.
"ZMZ-406 Turbo": tuning
The second way to improve the engine under consideration is to install the supercharger. In order for the device to withstand high pressure normally, a reinforced piston unit must be installed. The rest of the structure is identical to the transformations carried out during the atmospheric modernization.
A Garrett 28 turbine with a corresponding manifold, piping, intercooler, 630 cc injectors, exhaust system by 76 mm, DBP + DTV. The output power will result in at least 300 "horses". If desired, you can change the nozzles to the 800 cc configuration, which will further increase the engine power, however, such a system will lead to rapid wear of the unit. A new compressor will be required, such as the Eaton M90. Then you need to fine-tune it. As practice shows, such an upgrade allows you to get a motor without failures, the thrust of which is felt already from the bottom.
Intake system configuration
This operation with the use of a new timing set "ZMZ-406 Euro-2 Turbo" is one of the most important points affecting the parameters of the power plant. In the system under consideration, wave processes occur that are tuned to a specific speed range. In the standard version, the unit has ambiguous characteristics.
The pluses include a short intake tract, designed for high revs. On the other hand, the inlets on the filter have a fairly small cross-section. The filter element itself is different high performance and does not require replacement with a zero option, which is difficult to maintain and does not have high efficiency.
To improve performance and fill cylinders at high rpm, experts recommend removing the standard atmospheric filter housing. The solution to this problem is manifested in the installation of the "cold intake" system. At the place of installation of the air filter element, a closed volume is equipped in such a way that the air flow enters exclusively from the outside. An additional partition will help in this.
Alternatively, you can not fence off anything under the hood, but bring the air intake under the bumper. However, in this case, there is a risk of water hammer, while a slight decrease in motor power is noted.
Finalization of the cylinder head
This operation is reduced to grinding the channels, smoothing out all sharp residues in the combustion chamber and on the bottom of the piston. For the engines in question, it is recommended to install the cylinder head gasket from the unit 405.22 (Euro-3). It is made of solid metal and is more reliable and thinner. As a result, it allows for increased compression and engine economy.
The next step is to install the camshafts with increased valve travel. For regular operation of the power plant in urban conditions, experts advise using a pair of shafts of the 30/34 type.
Other ways to upgrade
The engine can also be improved by installing a timing kit "ZMZ-406 Euro2 Turbo". In addition, the crankshaft is mounted with an increased stroke of the crank assembly. This will make it possible to increase the working volume up to 2.5 liters. Additionally, with the new crankshaft, pistons are used with a pin offset by 4 millimeters. It should not go out of the plane of the block and hit the cylinder head.
A good option for power units the model under consideration is considered to be the use of pistons with thin rings. They will reduce dynamic losses, which is especially important for resourceful engines. Alternatively, you can tackle the lightening of the piston and connecting rod group, but this will not have much effect on motors with a speed of up to 7 thousand revolutions per minute. Reducing the mass of the flywheel on such samples leads to intermittent operation, a quick set of revolutions and the same intensive dropping. This is not very convenient, especially when moving around the city.
No matter how many horses there are under the hood of a car, there are always not enough of them. Although the power of the ZMZ 406 injection motor is technical data sheet is 145 liters. with., this is not enough for all car owners.
Today we will tell you about increasing the power of the ZMZ 406 engine with an injector.
Cars that have a 406 engine are usually heavy and therefore need a suitable powertrain to provide good driving dynamics.
What are the ways to increase the power of the ZMZ-406 injector?
Maximum cylinder bore, you can only harm the power unit and reduce its resource.
In general, a complete overhaul of the engine and the installation of pistons with less weight and a lightweight crankshaft is an expensive pleasure. Of course, the best option is to install a turbine on the motor.
Compared to other methods of increasing power, the turbine does less damage to the powertrain.
When used on the ZMZ-406, it will be possible to increase the engine power up to 200 hp. Also, meet today different kind turbochargers that are easy to install and do not need special attention from car owners.
Mechanical pressurization ZMZ-406
Increasing the power of the ZMZ 406 engine by mechanical supercharging.
All types of compressors can be roughly divided into 2 large groups: mechanically aspirated and turbocharged. Both of these types have their own pros and cons, and they also have their fans and opponents.
What type of compressor is best used for the ZMZ-406 engine? And in general, what is mechanical pressurization?
The principle of operation of mechanical pressurization is quite simple. Its design is reminiscent of an oil pump. It consists of two axles on which gears are located with meshing teeth.
By analogy with the ZMZ-406 oil pump, which creates pressure in the lubrication system, the compressor creates air pressure. The compressor is driven crankshaft motor.
Mechanical supercharging has several disadvantages. The most important is the significant decrease in efficiency due to the use of the crankshaft to drive the compressor, which leads to an increase in the load on the engine.
Due to the high pressure downstream of the compressor, the likelihood of air leaking back increases. To prevent this from happening, a multistage air supply is used with several pumps installed one after the other. However, this leads to a more complex and expensive design.
Turbocharging ZMZ-406
Increasing the power of the ZMZ 406 engine by turbocharging. The best performance for the ZMZ-406 injector is shown by turbocharging.
It does not have any belt drive from the crankshaft, and its design is much more reliable, cheaper and more unpretentious.
The principle of operation of turbocharging is extremely simple: inside the exhaust manifold there is an impeller driven by exhaust gases, and the number of turbine revolutions can exceed 200 thousand.
The turbine and air blower are located on the same axis together with the impeller, inside the exhaust manifold.
That is injection engine there is no 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 speeds, less exhaust gases... 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.
We talked about increasing the power of the ZMZ 406 engine with an injector, good luck on the road!
The domestic engine "ZMZ-406 Turbo" is a successor of the classic analogue, known under the index 402. New motor somewhat reminiscent of the Swedish "Saab", the body of the unit is made of cast iron, camshafts have a top location. The power plant includes 16 valves, hydraulic expansion joints. This design allows the owner to get rid of frequent adjustments valves. The timing drive is equipped with a chain, the nominal service life of which is at least 100 thousand kilometers. Despite the simplicity of the design, the considered installation is much more "advanced" than its predecessor. Let's study the features of the device and user reviews about it.
"ZMZ-406 Turbo": characteristics
Below are the parameters of the motor in question:
- Years of release - 1997-2008.
- The feed part is an injector / carburetor.
- The arrangement of the cylinders is in-line type.
- The number of cylinders and valves on each element is 4/4.
- Piston movement - 86 mm.
- Compression - 9.3.
- The volume of the "engine" is 2286 cubic meters. cm.
- The power indicator is 145 horsepower at 5200 rpm.
- The environmental standard is Euro-3.
- Weight - 187 kg.
- Fuel consumption in mixed mode is 13.5 liters per 100 km.
- The rated working life of the unit is 150 thousand kilometers.
- Installation - "Volga" 3102/31029/3110, (Gazelle, Sable).
Modifications
Several models of the ZMZ-406 Turbo engine were put into operation:
- Carburetor modification 406. 1. 10. Used on Gazelles, consumes AI-76 gasoline.
- Version 406. 2. 10. Injection motor, installed on "Gazelles" and "Volga".
- Model 406. 3. 10. Applied on "Gazelles" (AI-92).
Major malfunctions
The ZMZ-406 Turbo engine is most often subject to the following malfunctions:
- Hydraulic tensioners lend themselves to jamming. In this regard, there is extraneous noise, the absence of vibrations, further deformation of the shoe, up to the destruction of the entire chain. In this regard, the advantage of the engine under consideration is that the valves do not bend on it.
- Overheating of the power plant. This problem is also not uncommon. As a rule, such a breakdown occurs due to a clogged radiator or a failure of the thermostat. Initially, it is recommended to check the coolant level and the presence of air pockets in the system.
- Increased oil consumption. Most often, the ZMZ-406 Turbo KIT engine experiences this problem due to wear of the oil seals and oil scraper valves on the valves. Also, a malfunction sometimes occurs due to the fact that a gap forms between the plate and the valve cover, through which oil leaks. To fix the problem, it is enough to remove the cover and treat the surface with a sealant.
Other problems
Among other frequently occurring malfunctions of the ZMZ-406 Turbo engine, the following can be noted:
- Traction dips are often observed due to failure of the ignition coils. After replacing these elements, the performance of the motor is restored instantly.
- Knock in the power unit. This problem occurs due to wear on the hydraulic expansion joints. According to the manufacturer, the service life of these parts is calculated for at least 50 thousand kilometers.
- Wear of piston pins, pistons and which also leads to the occurrence of extraneous sounds in the motor.
- The power unit is troit. In this case, you should check the candles, coils and compression.
- The fading of the power unit is observed. Most often, "ZMZ-406 Turbo" stalls due to a malfunction of the wires, crankshaft sensor or IAC.
In addition, failures in the operation of the ZMZ-406 Turbo clutch and the fuel pump have been repeatedly observed. In general, the causes of problems are typical for all domestic motors, including poor build quality. Nevertheless, the 406th model is much more efficient and practical than its predecessor under the number 402. For reference: on the basis of the 406th "ZMZ", motors of the 405th and 409th series, with a volume of 2.7 liters, were developed.
Forcing
One of the options for the unit is the atmospheric method with the installation of additional shafts. At the inlet, a cold air intake is mounted, a receiver with an increased diameter. Then the cylinder head is sawn, the combustion compartments are refined, the size of the channels is increased. At the next stage of the improvement of the ZMZ-406 Turbo engine, lightweight T-valves, type 21083 springs and new shafts, for example, from OKB 38/38, are installed.
It makes no sense to use a standard tractor piston group. They acquire a new type, a lightweight crankshaft. Balancing the node. Adjustable straight-through exhaust on a pipe with a diameter of 63 mm. As a result, the power will be about 200 horsepower, and the characteristics of the power plant will have a pronounced sporty configuration.
"ZMZ-406 Turbo": tuning
The second way to improve the engine under consideration is to install the supercharger. In order for the device to withstand high pressure normally, a reinforced piston unit must be installed. The rest of the structure is identical to the transformations carried out during the atmospheric modernization.
A Garrett 28 turbine with a corresponding manifold, piping, intercooler, 630 cc injectors, 76 mm exhaust system, MAP + DTV is installed. The output power will result in at least 300 "horses". If desired, you can change the nozzles to the 800 cc configuration, which will further increase the engine power, however, such a system will lead to rapid wear of the unit. A new compressor will be required, such as the Eaton M90. Then you need to fine-tune it. As practice shows, such an upgrade allows you to get a motor without failures, the thrust of which is felt already from the bottom.
Intake system configuration
This operation with the use of a new timing set "ZMZ-406 Euro-2 Turbo" is one of the most important points affecting the parameters of the power plant. In the system under consideration, wave processes occur that are tuned to a specific speed range. In the standard version, the unit has ambiguous characteristics.
The pluses include a short intake tract, designed for high revs. On the other hand, the inlets on the filter have a fairly small cross-section. The filter element itself is characterized by high performance and does not require replacement with a zero version, which is difficult to maintain and does not have high efficiency.
To improve performance and fill cylinders at high rpm, experts recommend removing the standard atmospheric filter housing. The solution to this problem is manifested in the installation of the "cold intake" system. At the place of installation of the air filter element, a closed volume is equipped in such a way that the air flow enters exclusively from the outside. An additional partition will help in this.
Alternatively, you can not fence off anything under the hood, but bring the air intake under the bumper. However, in this case, there is a risk of getting a slight decrease in motor power.
Finalization of the cylinder head
This operation is reduced to grinding the channels, smoothing out all sharp residues in the combustion chamber and on the bottom of the piston. For the engines in question, it is recommended to install the cylinder head gasket from the unit 405.22 (Euro-3). It is made of solid metal and is more reliable and thinner. As a result, it allows for increased compression and engine economy.
The next step is to install the camshafts with increased valve travel. For regular operation of the power plant in urban conditions, experts advise using a pair of shafts of the 30/34 type.
Other ways to upgrade
The engine can also be improved by installing a timing kit "ZMZ-406 Euro2 Turbo". In addition, the crankshaft is mounted with an increased stroke of the crank assembly. This will make it possible to increase the working volume up to 2.5 liters. Additionally, with the new crankshaft, pistons are used with a pin offset by 4 millimeters. It should not go out of the plane of the block and hit the cylinder head.
A good option for the power units of the model in question is the use of pistons with thin rings. They will reduce dynamic losses, which is especially important for resourceful engines. Alternatively, you can tackle the lightening of the piston and connecting rod group, but this will not have much effect on motors with a speed of up to 7 thousand revolutions per minute. Reducing the mass of the flywheel on such samples leads to intermittent operation, a quick set of revolutions and the same intensive dropping. This is not very convenient, especially when moving around the city.
