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 sold in connection with the removal of cars from production.
ICE ZMZ 406
The ZMZ 402 (equipment) and the H-series engine of the SAAB manufacturer (design solutions) were taken as the basis. 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. from. power instead of the expected 150 hp, like the Swedish internal combustion engine. The injection system, which was later replaced by a carburetor, was able to correct the situation a little - 201 Nm and 145 hp. s., respectively.
Carburetor version ZMZ 4061.10
For the first time, several advanced technical solutions for that time were used in the engine of the manufacturer ZMZ:
- two intake and two exhaust valves per cylinder;
- electronic ignition and injection systems;
- diagram of the DOCH gas distribution mechanism with two overhead camshafts;
- hydraulic pushers instead of adjusting the thermal clearance of valves with gaskets.
Valve lifters
After the changes made, the technical characteristics of ZMZ 406 correspond to the values \u200b\u200bgiven in the table:
| Manufacturer | ZMZ |
| ICE brand | 406 |
| Years of production | 1997 – 2008 |
| Volume | 2286 cm 3 (2.3 l) |
| Power | 73.55 kW (100 HP) |
| Torque | 177/201 Nm (at 4200 rpm) |
| Weight | 192 kg |
| Compression ratio | 9,3 |
| Nutrition | injector/carburetor |
| motor type | in-line petrol |
| Ignition | switching |
| Number of cylinders | 4 |
| Location of the first cylinder | TVE |
| Number of valves per cylinder | 4 |
| Cylinder head material | aluminum alloy |
| Intake manifold | duralumin |
| An exhaust manifold | cast iron |
| camshaft | 2 pcs. DOCH scheme |
| 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 kind of 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 | Synthetic in winter, semi-synthetic in summer |
| Engine oil volume | 6.1 l |
| Operating temperature | 90° |
| ICE resource | claimed 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 |
| spark plug gap | 1.1mm |
| Valve train chain | 70/90 with shoe or 72/92 with sprockets |
| The order of operation of the cylinders | 1-3-4-2 |
| Air filter | Nitto, Knecht, Fram, WIX, Hengst |
| Oil filter | with check valve |
| Flywheel | 7 offset holes, 40 mm inner diameter |
| Flywheel mounting bolts | M12x1.25 mm, length 26 mm |
| Valve stem seals | Goetze, bright inlets dark graduation |
| Compression | from 13 bar, difference in neighboring cylinders max. 1 bar |
| Turnover XX | 750 - 800 min -1 |
| Tightening torque for threaded connections | candle - 31 - 38 Nm flywheel - 72 - 80 Nm clutch bolt - 19 - 30 Nm bearing cap - 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 precise description of the parameters:
- ZMZ 4063.10 - carburetor, compression ratio 8 for operation on A-76 fuel, power 110 hp. s., torque 186 Nm, weight 185 kg;
- ZMZ 4061.10 - carburetor, compression ratio 8 for A-76 gasoline, power 100 hp. s., torque 177 Nm, weight 185 kg;
- ZMZ 4062.10 - injector, compression ratio 9.3 for AI-92 fuel, power 145 hp. s., 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. Received microprocessor ignition, DOCH gas distribution scheme with a two-stage chain drive.
The developers still used an in-line engine layout with 4 cylinders, but there were two camshafts, they are located on top, inside the cylinder head. The compression ratio of the internal combustion engine was increased by the plant designers to 9.3 in the basic version 4062.10 due to the central location of the candle inside the combustion chamber.
The design of the gas distribution mechanism
Reliability is enhanced by a cast-iron cylinder block without liners, a reduction in piston stroke to 86 mm and the weight of the entire group of SHPGs. Bolted connecting rods, crankshaft and piston rings are made from high strength materials, so major repairs are less frequently required.
Timing chain tensioner
Chain tensioners are automatic, double acting - preloaded by a spring 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 engine modifications
Initially, the motor was designed with injection, so version 4062.10 is considered the base one. The need for carburetor modifications 4061.10 and 4063.10 arose later. They were installed on the Gazelle, therefore, while maintaining the volume of the combustion chambers, it was necessary to reduce the operating costs of the owner. To do this, the management of ZMZ lowered the compression ratio in order to transfer the engines to cheaper A-76 fuel.
Versions of the ZMZ 406 engine differ in combustion chambers
With motors 4061 and 4063, a reverse modernization was made:
- reduced power and torque;
- revolutions XX steel 750 min -1 instead of 800 min -1 ;
- maximum torque is reached at 3500 rpm, not at 4000.
Everything else mounted is 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 ZMZ 406 power drive is the low quality of casting and unsuccessful technical solutions:
- high oil consumption due to the unfinished design of the rings;
- low timing resource of the drive due to the tensioner, collapsible block star and bulky design in general.
Fuel consumption is high, but this is typical for most truck engines.
But vibrations are reduced, the cylinder head does not unscrew during operation, the gasket does not need to be constantly changed, and the nuts need to be tightened. The maintainability of all nodes is high, the design itself is reliable and simple. The user is relieved of the need to adjust the valve clearances every 20,000 runs.
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 GAZ car manufacturer:
- 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 engine characteristics were suitable for the urban executive cars of officials and the government. Carburetor modifications reduced the operating budget of Gazelle vans, utility cars and trucks.
Maintenance schedule ZMZ 406 2.3 l / 100 l. from.
According to the manufacturer's requirements, the ZMZ 406 engine is serviced in the following order:
- inspection of the timing chain after 30,000 runs, replacement after 100,000 km;
- oil and filter change after 10,000 km;
- coolant replacement approximately every two years or 30,000 mileage;
- recharging the battery every autumn, replacing after 50,000 km;
- spark plugs last for 60,000 runs;
- the fuel filter becomes unusable after 30,000 km, the air filter - 20,000 km;
- ignition coils fail after 50,000 runs.
Repair 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 high-life, with the exception of the pump, the polymer rotor of which lasts about 30,000 km. Due to the heavy weight of the motor with your own hands, it is very difficult to overhaul in a garage without a hoist.
Overview of faults and how to fix them
Due to the design features, the ZMZ 406 motor bends the valve only when the chain jumps. Moreover, they are damaged against each other (inlet and outlet while lifting), and not about the pistons. If the circuit breaks, this trouble will not happen.
Since the ICE device is partially copied from SAAB, and the ZMZ 402 design is partially preserved, it is characterized by malfunctions:
| High RPM XX | 1) sensor failure 2) there is no contact of the regulator XX 3) torn crankcase ventilation hoses |
1) replacement of sensors 2) contact recovery 3) replacement of hoses |
| Cylinder failure | 1) ECU malfunction 2) failure of the coil 3) breakdown of the tip of the candle 4) nozzle failure |
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 suction 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) fuel supply is broken |
1) replacement of the coil, contact 2) replacement of the filter, pressure reducing 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, so the level of working fluids should be monitored regularly (oils and antifreeze).
Motor tuning options
Initially, the ZMZ 406 engine allows you to increase the power on your own up to 200 - 250 hp. from. 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 necessary).
Tuning ZMZ 406
For Gazelle minibuses and trucks, turbo tuning is ineffective, since the operational 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, primarily to increase torque.
Family ZMZ-406 is a gasoline automobile internal combustion engine manufactured by OAO Zavolzhsky Motor Plant.
Prototypes have been assembled since 1992, in serial production since 1997.
Fuel injection was used for the first time.
This family of engines was widely used on cars of the Gorky Automobile Plant, such as: Volga -3102, 31029, 3110 and GAZelle.
The flagship of the family - ZMZ-4062.10 - a 16-valve engine with a volume of 2.28 liters, capable of developing power up to 150 hp.
The ZMZ-4062.10 engine is designed for installation on cars middle class and minibuses.
Engines ZMZ-4061.10, ZMZ-4063.10 are designed for installation on trucks light-duty type "Gazelle" and minibuses.
Specifications
| Parameter name | ZMZ-4062 | ZMZ-4061 | ZMZ-4063 | ZMZ-4052 | ZMZ-409 |
|---|---|---|---|---|---|
| Working volume, l | 2,3 | 2,46 | 2,69 | ||
| Cylinder diameter, mm | 92 | 95,5 | |||
| Piston stroke, mm | 86 | 94 | |||
| Compression ratio | 9,1 | 8,0 | 9,5 | 9,3 | 9,0 |
| Supply system | Injection | Carburetor | Injection | ||
| Rated power, kW (hp) | 110,3 (150) | 73,5 (100) | 80,9 (110) | 118,8 (152) | 105 (142,8) |
| 5200 | 4500 | 4500 | 5200 | 4400 | |
| Max. torque, N*m (kgf*m) | 206 (21) | 181,5 (18,5) | 191,3 (19,5) | 210,0 (21,5) | 230 (23,5) |
| Speed at nom. power, min-1 | 5200 | 4500 | 4500 | 5200 | 4400 |
| Speed at max. torque, min-1 | 4000 | 3500 | 3500 | 4300 | 3900 |
| Idling speed, min-1 (min + -50 / max) | 800 / 6000 | 750 / 6000 | 850 / 6000 | 850 / 5000 | |
| Minimum specific fuel consumption, g/kW*h (g/hp*h) | 252 (185) | 273 (200) | 265 (195) | ||
| The order of operation of the cylinders | 1-3-4-2 | ||||
| Oil consumption for waste, % of fuel consumption | 0,3 | 0,4 | 0,3 | ||
| Weight of the engine supplied by the factory, kg | 187 | 185 | 187 | 190 | |
Engines ZMZ-4061, ZMZ-4063
- carburetor, four-cylinder, in-line with a microprocessor ignition control system.
A general view of the engines is shown in Figure 1 and 3.
The cross section of the engines is shown in Figure 2.
Picture 1.
Engines of the ZMZ-4061 and ZMZ-4063 models (view from the left side)
- drain plug;
- oil sump;
- an exhaust manifold;
- engine support bracket;
- coolant drain valve;
- water pump;
- coolant emergency temperature sensor;
- coolant temperature indicator sensor;
- engine temperature sensor;
- thermostat housing;
- emergency oil pressure sensor;
- oil pressure indicator sensor;
- oil level indicator (dipstick);
- ignition coil
Figure 2.
- 1 - oil sump;
- 2 - oil pump receiver;
- 3 - oil pump;
- 4 - oil pump drive;
- 5 - intermediate shaft gear;
- 6 - cylinder block;
- 7 - inlet pipe;
- 8 - ventilation pipes;
- 9 - intake camshaft;
- 10 - inlet valve;
- 11 - valve cover;
- 12 - exhaust camshaft;
- 13 - oil level indicator (dipstick);
- 14 - hydraulic valve pusher;
- 15 - outer spring of the valve;
- 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 cap;
- 26 - drain plug;
- 27 - pusher body;
- 28 - guide sleeve;
- 29 - compensator housing;
- 30 - retaining ring;
- 31 - compensator piston;
- 32 - ball valve;
- 33 - ball valve spring;
- 34 - body of the ball valve;
- 35 - expanding spring
Figure 3
- synchronization disk;
- synchronization sensor;
- oil filter;
- starter;
- knock sensor;
- coolant drain pipe from the heater;
- inlet pipe;
- chain tensioner;
- generator;
- generator belt;
- water pump pulley;
- tension roller;
- gasoline pump
The main design features of the engines are the top (in the cylinder head) arrangement of two camshafts with the installation of four valves per cylinder (two intake and two exhaust), an increase in the compression ratio to 9.3 due to the combustion chamber with a central location of the candle.
These technical solutions made it possible to increase the maximum power and maximum torque, reduce fuel consumption and reduce the toxicity of exhaust gases.
To improve reliability, the engine uses a cast-iron cylinder block without insert liners, which has high rigidity and more stable clearances in friction pairs, the piston stroke is reduced to 86 mm, the mass of the piston and piston pin is reduced, better materials are used for the crankshaft, connecting rods, connecting rod bolts , piston pins, etc.
Camshaft drive - chain, two-stage, with automatic hydraulic chain tensioners; the use of hydraulic pushers of the valve mechanism eliminates the need to adjust the gaps.
The use of hydraulic devices and forcing the engine require high quality oil cleaning, so the engine uses a single-use full-flow oil filter ("superfilter") of increased efficiency. The additional filter element of the filter prevents untreated oil from entering the engine when starting a cold engine and clogging the main filter element.
The microprocessor ignition control system allows you to adjust the ignition timing, including the detonation parameter under changing engine operating modes, which allows you to provide the necessary indicators - power, economic and exhaust gas toxicity.
The auxiliary units (coolant pump and alternator) are driven by a flat V-ribbed belt.
The engine is equipped with a diaphragm clutch with elliptical-wound linings of the driven disk, which have a high durability.
In 2004. The new car has undergone significant changes, but much remains from its predecessor. In particular, the ZMZ 402 and ZMZ 406 engines were installed on the new Volga from the very beginning.
ZMZ 402 engine in section
Later, the line of engines changed to 31105 - since 2006, the “one hundred and fifth” models with the “Chrysler” engine with a volume of 2.4 liters went into the series, and a ZMZ 405 power unit with a volume of 2.5 liters was also added.
It is strange that in general this internal combustion engine ended up on a new car - you can’t equip cars with the same engine for so many years. For the first time, this engine began to be serially installed on a transitional engine in 1985, and since that time it has not undergone practically any changes. However, it came from the factory in 2004 and 2005.
Replacing the oil filter in the ZMZ-402 engine
But the ZMZ 402 ICE still had its advantages. Firstly, it has a lower price, and the car bundled with it, respectively, is cheaper. Secondly, car owners were bribed by the simplicity of the motor. For so many years of production, the power unit has been studied up and down by many owners, and sometimes it was repaired almost in the field.
Of all, the 402nd motor is the most low-power and low-speed. It has its own characteristic malfunctions, which are most often encountered:
- Oil leakage from the rear main bearing (from the gland packing);
- Increased oil loss through piston rings;
- Breakage of the hex drive of the oil pump;
- Loss of valve seats in the cylinder head.
If many shortcomings could somehow be put up with, then the valve seat falling out became a real disaster for the car owner.
Disassembly of the ZMZ 402 engine
The saddle most often crumbled into small pieces and scattered over all cylinders. As a result, it was necessary to change the block head and piston group, without fail, thoroughly clean the intake manifold and carburetor. Seat loss is a technological defect of the plant; this almost never occurs on any other motors. By the way, 3M3 402 on the Volga 31105 was the only engine that had a carburetor system, all other internal combustion engines were equipped with an injection-type fuel system.
The undoubted advantage of the 402nd is that almost any engine oil can be poured into it. Taxi drivers, in order to save money, went so far as to fill the engine with the cheapest Kamaz oil and M8 autolok. Moreover, topping up was done with the oil that was at hand. 
It only remained to wonder how this engine was still working - when disassembling, often after such operation, one could observe not only soot on all the internal parts of the 402nd, but also curdled grease like “great oil”.
Read also
Cooling and heating radiators for GAZ-31105
In total, the 402nd engine was produced in two versions:
- To work on AI-92 gasoline - ZMZ 402;
- For operation on A-76 gasoline - ZMZ 4021.
The derated ZMZ 4021 engine has an enlarged combustion chamber, and all its difference from the ZMZ 402 lies only in the cylinder head, which is 4 mm higher.
Technical characteristics of the internal combustion engine ZMZ 402:
ZMZ 406
By the time the ZMZ 406 engine appeared on the Volga 31105, it had already been well tested on the previous model 3110, and proved itself mostly on the positive side. The ICE 406 has been serially installed on the Volga 3110 since 1997, and with a smaller volume (2.3 liters) it had more power and better torque. True, due to the presence of an electronic control system, ZMZ 406 added new problems - sensors and ECUs often failed, breaks and short circuits occurred in the engine compartment wiring.
This is how the ZMZ 406 engine ready for installation looks like
Some malfunctions could be identified by error codes when the ignition was turned on, but it was already impossible for an ordinary vehicle user to deal with the electronics on their own. Diagnostics is mainly carried out by car owners of the Volga with the 406th engine at a specialized service station.
The 406th had its own "sores":
- Chains and other parts of the gas distribution mechanism wore out relatively quickly;
- Often the timing chain tensioners jammed;
- Electric remote fuel pumps periodically failed;
- At the slightest overheating, the head gasket burned out, and the head itself often jarred.
In the design of ZMZ, the design of the timing chain tension is not thought out. The top chain shoe extension is heavily loaded and often breaks off.
Timing chain on the ZMZ 406 engine
Breaking it causes a lot of problems:
- Firstly, its remnants have to be drilled out of the cylinder block;
- Secondly, the chains break, and laborious repairs have to be made.
Read also
ZMZ 406 engine installed on a GAZ-31105 car
Jamming of the upper tensioner also contributes to the breaking of the chains. But first, with a faulty tensioner, the sound of a “running diesel” appears. If the car owner, ignoring the noise, continues to drive, as a result, he gets to repair - the replacement of timing chains.
Exceeding the temperature of the coolant with the ZMZ 406 engine must not be allowed - the cylinder head bolts quickly loosen, and the head gasket breaks down. The surface of the cylinder head often warps - in some cases it is milled on the machine, but often the head has to be changed. The cylinder head has a tangible price, and as a result, repairs are expensive.
Disassembled motor ZMZ 406
Interestingly, the 406th has practically nothing in common with the 402nd engine, if only the engine mounts remained the same. ZMZ 406 is more demanding on engine oil, you can’t fill it with autol. The following can be noted about attachments: the starter is quite reliable and does not break often, but the generator is the weak link.
More about fuel pumps - on the 406th engines they are mostly external, and are installed under the bottom of the car next to the gas tank.
On the first 3110 models, the plant equipped the car with Bosch gasoline pumps, these parts were highly reliable. But then Russian spare parts began to be produced - so they became problematic for GAZ 3110 and GAZ 31105.
Often the engine control unit on the ZMZ 406 engine fails. A malfunction can be detected in different ways - the engine starts to triple, not develop speed.
Engine control circuit ZMZ-406
Often, the failure of the ECU leads to the fact that the internal combustion engine does not start at all.
Specifications ZMZ 406:
- Type - injector;
- Rated power - 133 liters. from.;
- Recommended fuel - AI-92 and AI-95 gasoline;
- Cylinder volume - 2.3 l;
- The number and arrangement of cylinders - 4 in one row;
- The number of valves per cylinder - 4;
- Compression in the cylinders - 9.3;
- Piston diameter - 92 mm;
- Piston stroke - 86 mm;
- Weight (with attachments) - 187 kg;
- Oil in the crankcase - 5 liters.
In this article you will find:
ZMZ 406 engine. Let there be injection!
ZMZ 406, in fact, is not as young as is commonly believed. Developments on a revving overhead motor for large machines were started back in the USSR. Even then it was clear that with all the wonderful qualities of the family of engines and its predecessors, you need to move forward.
There were two ways:
- Leave the old block and, while maintaining the general engine layout, work on a modern body kit;
— Create a completely new motor.
Supporters of the first scheme were found in Ulyanovsk, where an injection system would later be created. The motor is good and very convenient in terms of the absence of technical problems of installing it on old cars, which indescribably pleased the supporters of progress in the camp of GAZ 21 owners (the motor is installed easily and naturally, docking with native fasteners, gearboxes, etc.).
ZMZ engineers, in turn, chose option number two and started designing the engine from scratch.
Creation
According to one version, the ZMZ 406 and its counterparts appeared as a result of direct copying and further work on the DEGRADATION of the SAAB 9000 B234i engine. unusable. Unfortunately, in this rather widely disseminated legend, neither specific names, nor documents, nor any other verifiable confirmations of the truth are given. Perhaps the only thing that could really testify in favor of this version is the external similarity of the engines and the same working volume. You can read more about this branch of alternative reality on a variety of resources, from UAZbuka and drive2, to drom and Maylov's "Answers" project. The article is the same everywhere. This information is not found anywhere else from available sources.
We will consider a different history of the emergence of this motor. An attempt to transfer the camshaft from the cylinder block to the head was made even at the stage of work on the GAZ 21 engine, but the design turned out to be not very reliable, and the engine went into series in the lower version and retained this design up to the ZMZ 402 engine. Design work on the new engine will start in the late 80s of the last century. Difficult times began, and therefore, the development and refinement of the motor dragged on until the early 90s. The motor went into a small series only in 1992. The plans were quite ambitious, and the new engine was supposed to be offered not only to the traditional partner represented by the Gorky Plant, but also to AZLK, BAZ and even VAZ. However, the economy was falling apart before our eyes, factories were barely surviving, and there was no talk of putting new machines on the conveyor. As a result, only GAZ became the consumer of the novelty.
Large-scale production began only in 1996 and reached significant volumes only by 1997.
Design and features
Petrol engine, four-cylinder, sixteen-valve, in-line with distributed fuel injection and microprocessor control system. Power 145 hp at a crankshaft speed of 5200. The working volume is 2.28 liters.
The block is cast iron, the cylinders are made by a groove directly in the body of the block. This decision made it possible to make the block very rigid, and the gaps in the friction pairs became more stable. Nevertheless, the possibility of its repair boring is provided (three repairs are allowed).
Closed crankcase ventilation, forced.
The crankshaft made of magnesium cast iron rotates in five bearings on plain bearings. Longitudinal movement of the shaft is limited by thrust half rings installed in the selections of the third main bearing. Both ends of the shaft, to the delight of car mechanics, are sealed with self-compressing rubber or silicone seals.
Cast aluminum pistons with two compression rings and one integral oil scraper ring. Steel I-section connecting rods, with a split lower head on a plain bearing. Piston pins of a floating type, not fixed either in the piston or in the upper head of the connecting rod. Longitudinal movement is limited only by retaining rings. The piston stroke is reduced to 86 mm. The piston diameter remained the same - 92 mm.
The lubrication system of the ZMZ 406 engine is full-flow, combined. The bushings, plain bearings and hydraulic tappets are pressure lubricated, while the cylinder walls are splash lubricated. The oil pump is gear, single-section with a rather original drive design. Traditionally, the oil pump shaft is driven either by a gear from the crankshaft, or through helical gears from the camshaft, but ZMZ engineers did not find such solutions interesting enough, and they went their own way. The drive rotates from the timing intermediate shaft driven by the chain. It turned out quite cumbersome, but in general it is quite reliable. Motorists, in general, consider this innovation to be wrecking, perhaps they are right. The pressure reducing valve opens at a pressure in the system of 0.7-0.9 kgf / cm2, directing oil to the oil cooler, from where it flows into the engine crankcase. .
The cooling system is closed type, works under excess pressure.
Due to the higher degree of forcing, the engine is quite demanding on the quality of engine oil and needs a more serious attitude to maintenance than its predecessors.
The head of the block is cast from an aluminum alloy. Tent-type combustion chamber with four valves per cylinder. The valve mechanism received hydraulic pushers, which saved motorists from having to adjust the valves. The intake and exhaust manifolds are spaced apart on opposite sides of the head.
Camshafts are now also located in the head, there are two of them, one works with intake valves, the second with exhaust valves. Cast iron shafts rotate on five bearings in plain bearings. The longitudinal movement of the shafts is limited by plastic thrust half rings in the front cover and front bearings. The shaft drive is chain, two-stage with the use of an intermediate shaft. The chain of the upper stage has 70 links, the lower one - 90. The tension of the chains is regulated by automatic hydraulic tensioners with thrust shoes made of wear-resistant plastic. In the future, the shoes were replaced with levers with stars, which increased the resource of the mechanism between repairs. Please note that chains with different types of tensioners are not interchangeable.
Cast iron exhaust manifold.
The intake manifold is cast from aluminum, a receiver is mounted on it, to the flange of which a throttle assembly with a cable drive is attached. The throttle is heated from the engine cooling line.
Fuel is supplied to the combustion chambers through individual nozzles (ported injection). Electronic injection control.
The ignition system is microprocessor. Based on the readings of engine sensors.
Over the years, engine control units MIKAS-5.4, MIKAS-7.1, ITELMA VS 5.6, SOATE were used. Accordingly, some sensors also changed, in particular the DMRV.
Modifications and applicability of ZMZ 406 engines
The engine was put on cars:
Volga 3102;
Volga 3110;
Volga 31105;
Gazelle;
Sable.
In addition, the ZMZ 406 is quite successfully installed by many motorists under the hoods of the twenty-fourth Volga family. To do this, you have to remove the right amplifier of the engine shield (interfering with the receiver), change the wiring, put other indicators in the dashboard, or change the entire panel (the fasteners do not match, but nothing that a purposeful person can not handle). It is also desirable to replace the gas tank, since the operation of an electric fuel pump requires an anti-drain bowl, which is not available in old-type tanks, without it, the fuel pump picks up air during braking and acceleration. When replacing the tank, it will be necessary to adjust the filler neck.
There are known cases of installing an engine on UAZ cars instead of ZMZ 409, however, such an alteration is very controversial, since a motor with a pronounced moment on the bottoms is more relevant for an SUV.
There are several modifications of ZMZ 406:
ZMZ 4062.10 - injection engine for running on A92 gasoline. The compression ratio is 9.3. It is intended for installation on cars.
ZMZ 40621.10 is a modification of the 4062.10 engine that complies with EURO-2 environmental standards.
ZMZ 4063.10 is a carbureted version of the engine designed for installation on light commercial trucks and minibuses. Power reduced to 110 hp
ZMZ 4061.10 - carburetor engine for light commercial vehicles. The compression ratio has been reduced to 8, for operation on A80 gasoline. Power - 100 hp
Generalization
To date, the engine has been produced with a circulation of more than one and a half million, it is the most common engine for light commercial vehicles in Russia.
ZMZ 406 was originally designed as the basis for a whole family of new engines for a wide variety of equipment. It has a huge potential for modernization and construction of engines with different characteristics on its basis. So it served as the basis for the creation of motors of the ZMZ 409 and ZMZ 405 families.
The disadvantages of the family include:
sagging of valve seats during long-term operation of the engine on a lean mixture or on gas fuel;
a bulky timing mechanism that does not have a very long resource (mainly, the drive chain tensioning system causes complaints; however, at the moment there are several sets from different manufacturers that allow improving this unit);
the control unit from SOATE with its unreliable DMRV is also criticized a lot (especially often problems arise when using gas fuel);
and the main problem that is also inherent in other modern ZMZ engines is the very low quality of spare parts, some of them are produced using technologies that are unacceptable in this case.
In general, the ZMZ 406 is a very reliable and maintainable engine, often outliving the body of the car on which it is installed. Of course, it is more complex, requires timely care and high-quality oil, and many of its components can no longer be repaired “on the knees with a hammer”. However, with the appropriate tool, it does not cause any particular problems, and spare parts are available everywhere.
The ZMZ-406 engine and its modifications have been mass-produced in the industrial production of ZMZ OJSC since 1996, and are intended for installation in GAZ passenger cars, such as GAZ-31105, GAZ-3102 and "". The engine requires professional maintenance due to the complex fuel supply system and electronic control system.
Characteristics of the engine ZMZ-406 2.3 16V Volga, Gazelle, Sable
| Parameter | Meaning |
|---|---|
| Configuration | L |
| Number of cylinders | 4 |
| Volume, l | 2,280 |
| Cylinder diameter, mm | 92 |
| Piston stroke, mm | 86 |
| Compression ratio | 9,3 |
| Number of valves per cylinder | 4 (2-inlet; 2-outlet) |
| Gas distribution mechanism | DOHC |
| The order of operation of the cylinders | 1-3-4-2 |
| Rated engine power / at engine speed | 106.6 kW - (145 hp) / 5200 rpm |
| Maximum torque / at revs | 200.9 Nm / 4500 rpm |
| Supply system | distributed injection with microprocessor control |
| Recommended minimum octane number of gasoline | 92 |
| Environmental regulations | Euro 0 |
| Weight, kg | 192 |
Design
Four-stroke engine with electronic fuel injection and ignition control, in-line arrangement of cylinders and pistons rotating one common crankshaft, with two overhead camshafts. The engine has a closed-type liquid cooling system with forced circulation. Combined lubrication system: under pressure and spray.
Cylinder block
The ZMZ-406 cylinder block is cast from gray cast iron. On the upper plane of the cylinder block of the ZMZ-406 engine there are ten M14x1.5 threaded holes for mounting the cylinder head. In the lower part of the ZMZ-406 block there are five crankshaft main bearing supports.
When repairing cylinders, two repair sizes are provided: 1st and 2nd. Pistons and piston rings are produced with the same repair dimensions.
Crankshaft
The crankshaft is cast from high-strength cast iron VCh60 (more durable in relation to VCh50), has a full support structure and eight counterweights (two counterweights for each crank for better unloading from centrifugal forces and bending moments).
Piston
| Parameter | Meaning |
|---|---|
| Diameter, mm | 92,0 |
| Compression height, mm | 38,0 |
| The volume of the internal recess, ss | 2,66 |
| Weight, g | 431 |
Pistons according to the outer diameter of the skirt and cylinders according to the inner diameter are sorted into two size groups (1st and 2nd). Piston pin of floating type, pin outer diameter 22 mm, length 64 mm. The whole finger is 121g.