The ZMZ 406 engine was developed on replacing the motor 402 simultaneously with the design of the GAZ-3105 car for the government. However, these new Volga cars were completed with them, which was necessary to urgently implement in connection with the removal of machines from production.
The basis of the ZMZ 402 (equipment) and the SAAB manufacturer's H series engine (design solutions) were taken. As a result, with the same volume of 2.3 l, the power actuator provided 177 nm of torque instead of 210 nm prototypes and 100 liters. from. Power instead of the expected 150 hp, like a Swedish engine. The injection system, which later replaced the carburetor, was able to fix the position a little - 201 nm and 145 liters. s., respectively.
Technical characteristics of ZMZ 406 2.3 l / 100 liters. from.
For the first time in the engine of the manufacturer of ZMZs, several advanced technical solutions were used:
- two intake and two exhaust valves per cylinder;
- electronic ignition and injection systems;
- scheme of the DOCH gas distribution mechanism with two upper camshafts;
- hydraulic drivers instead of adjusting the thermal clearance of valves with gaskets.
After the changes made, the technical characteristics of the CMZ 406 correspond to the values \u200b\u200bgiven in the table:
| Manufacturer | ZMZ. |
| Mark DVS | 406 |
| Years of production | 1997 – 2008 |
| Volume | 2286 cm 3 (2.3 l) |
| Power | 73.55 kW (100 l. P.) |
| Torque moment | 177/201 nm (at 4200 rpm) |
| Weight | 192 kg |
| Compression ratio | 9,3 |
| Food | injector / carburetor |
| Motor Type | in line gasoline |
| Ignition | switter |
| Number of cylinders | 4 |
| The location of the first cylinder | Twue |
| Number of valves on each cylinder | 4 |
| Material GBC. | aluminum alloy |
| Intake manifold | durally |
| Exhaust manifold | cast iron |
| Camshaft | 2 pcs. DOCH Scheme |
| Cylinder block material | cast iron |
| Diameter of the cylinder | 92 mm |
| Pistons | original |
| Crankshaft | lightweight |
| Piston move | 86 mm |
| Fuel | AI-92 / A-76 |
| Ecology standards | Euro-3 / Euro-0 |
| Fuel consumption | route - 8.3 l / 100 km mixed cycle 11.5 l / 100 km city - 13.5 l / 100 km |
| Oil consumption | maximum 0.3 l / 1000 km |
| What oil pour into a viscosity engine | 5W30, 5W40, 10W30, 10W40 |
| Which oil is better for the engine by manufacturer | Liqui Moly, Lukoil, Rosneft |
| Oil for ZMZ 406PO composition | winter synthetics, summer semi-synthetic |
| Motor oil volume | 6.1 L. |
| Working temperature | 90 ° |
| RF resource | submitted 150,000 km real 200000 km |
| Adjustment of valves | hydraulician |
| Cooling system | forced, antifreeze |
| Volume of oh | 10 L. |
| water pump | with plastic impeller |
| Candles on ZMZ 406 | domestic A14 DVRM or A14DVR |
| Candle clearance | 1.1 mm |
| Valve train chain | 70/90 with shoe or 72/92 with asterisks |
| The order of the cylinders | 1-3-4-2 |
| Air filter | Nitto, Knecht, Fram, Wix, Hengst |
| Oil filter | with check valve |
| Flywheel | 7 Holes with displacement, 40 mm Inner diameter |
| Fastening bolts flywheel | M12x1.25 mm, Length 26 mm |
| Valve stem seals | Goetze, bright intake, dark prom |
| Compression | from 13 bar, difference in adjacent cylinders maximum 1 bar |
| Turnover XX | 750 - 800 min -1 |
| Thinking force threaded connections | candle - 31 - 38 nm flywheel - 72 - 80 nm clutch bolt - 19 - 30 nm bearing cover - 98 - 108 nm (root) 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 fuel A-76, Power 110 l. s., torque 186 nm, weight 185 kg;
- ZMZ 4061.10 - carburetor, compression ratio 8 under gasoline A-76, power 100 liters. s., torque 177 nm, weight 185 kg;
- ZMZ 4062.10 - Injector, compression ratio 9.3 for fuel AI-92, Power 145 liters. p., torque 201 nm, weight 187 kg.
Design features
Officially, the ZMZ 406 engine became the third after 24d and 402 in the line of power drives of the Volga factory. Received microprocessor ignition, DOCH gas distribution scheme with two-stage chain drive.
The developers continued to use the inline engine circuit with 4 cylinders, but the camshafts were two, they are located on top, inside the CCC. The degree of compression of the engine is increased by plant designers to 9.3 in the basic version 4062.10 due to the central location of the candle inside the combustion chamber.
Reliability is raised due to the cast-iron cylinder block without a sleeve, reduce the stroke of the piston to 86 mm and the weight of the entire SPG group. Bolt rods, crankshaft and piston rings are made of high-strength materials, so overhaul is required less often.
Chain tensioners automatic, double action - pre-tension spring, while working hydraulics. The degree of oil purification is increased by installing a full-flow disposable filter. For hinged equipment there is a separate clinoremable drive. ECU firmware complies with SATE versions, ITELM VS5.6, Mikas 5.4 or 7.1
The list of modifications of the DVS
Initially, the engine was designed injector, so the version 4062.10 is considered basic. The need for carburetor modifications 4061.10 and 4063.10 appeared later. They were installed on the Gazelle, so retaining the volume of combustion chambers, it was necessary to reduce the operating costs of the owner. For this, the management of ZMZ reduced the compression ratio to translate the motors to cheaper fuel A-76.
Motors 4061 and 4063 produced reverse modernization:
- reduced power and torque;
- turnover of XX steel 750 min -1 instead of 800 min -1;
- the maximum torque is achieved by 3,500 revolutions, and not 4000.
Everything else is mounted on the same places unchanged. Part of the details are interchangeable, with the exception of the GBC and Piston.
Pros and cons
The negative feature of the power actuator ZMZ 406 is the low quality casting and unsuccessful technical solutions:
- high oil consumption due to the undermined rings design;
- low drive timing resource due to tensioner, collapsible block stars and cumbersome design as a whole.
Fuel consumption is high, but it is typical for most truck motors.
But the vibrations are reduced, the head of the cylinder block is not unscrewed during operation, the gasket does not need to be constantly changing, but the nuts stretch. Maintainability of all nodes are high, the design itself is reliable and simple. The user is disposed of need every 20,000 mileage to adjust valve gaps.
List of car models in which installed
Since the Motor ZMZ 406 has three versions, each of them was used on specific models of the manufacturer of the manufacturer GAZ:
- ZMZ 4062.10 - gas 31054 Suite configuration; GAZ 3102 (1996 - 2008);
- ZMZ 4061.10 - gas 3302, 33023, 2705, 3221;
- ZMZ 4063.10 - GAZ 3302, 33023, 2705, 3221, 32213, 322132, 32214, semar 3234, Ruta, Bogdan and Dolphin.
In the first case, the engine characteristics were suitable for the urban cycle of representative cars of officials and governments. Carburetor modifications reduced the operational budget of vans gazelles, cargo-passenger cars and trucks.
Rules of service ZMZ 406 2.3 l / 100 liters. from.
According to the manufacturer's requirements, the ZMZ 406 engine is serviced in the following order:
- inspection of the timing chain after 30000 mileage, replacement after 100,000 km;
- replacing oil and filter after 10,000 km;
- replacement of coolant approximately every two years or 30,000 runs;
- recharging the battery each autumn, replacement after 50000 km;
- ignition candles are enough for 60,000 run;
- fuel filter comes in disrepair after 30000 km, air - 20,000 km;
- the ignition coils fail after 50000 mileage.
The manufacturer recommends using high-quality lubricant for engines so that hydrocomathers and oil pumps work properly. Initially, the cooling system has weaknesses - radiator and thermostat. All hinged equipment is highly resource, with the exception of the pump, the polymer rotor of which serves about 30,000 km. Because of the big weight of the engine, with their own hands, the overhaul is very difficult in the garage without a telfer.
Overview of faults and ways to repair
By virtue of the structural features, the Motor ZMZ 406 turns the valve only when leaving the chain. Moreover, they are damaged by each other (intake and graduation with simultaneous lifting), and not about the pistons. When breaking the chain of such trouble will not happen.
Since the DVS device is partially copied with the Saab, and the construct of the ZMZ 402 is partially saved, the fault is characterized for it:
| High turnover XX | 1) damage sensors 2) no contact of the xx regulator 3) Torn Carter ventilation hoses | 1) sensor replacement 2) contact recovery 3) hose replacement |
| Cylinder failure | 1) Malfunction ECU 2) failure of the coil 3) Candle tip breakdown 4) breakdown nozzle | 1) Replacing the control unit 2) Repair coil 3) replacement of the tip 4) repair / replacement nozzle |
| Unstable work of the DVS | 1) air seats 2) water in the fuel tank | 1) Restoration of tightness, replacement of gaskets 2) gasoline drainage, dried tank |
| Motor does not start | 1) failure of the ignition system 2) Fuel supply is broken | 1) replacement coil, contact 2) Replacing the filter, reducing valve, phase adjustment, fuel pump replacement |
Due to the large diameter, the pistons block and the CCC are sensitive to overheating, so control the level of working fluids should be regularly (oil and antifreeze).
Motor tuning options
Initially, the ZMZ 406 engine allows you to increase the power with its own forces up to 200 - 250 liters. from. To do this, use mechanical tuning:
- installing the zero resistance filter;
- reduced air temperature in the intake path;
- replacing the standard carburetor K-16D Solex (needed adjusting the quality / quantity screws).
For minibuses and trucks, the Gazelle Tuning turbocharging is inffective, because the operational resource of the DS is reduced and the fuel consumption increases sharply.
Thus, the injector modification of the ZMZ 4062.10 and the carburetor versions of 4061.10, 4063.10 are based on the Swedish engine of the N series for trucks and the representative of the car. Tuning is allowed, first of all, to increase torque.
If you have any questions - leave them in the comments under the article. We or our visitors will gladly respond to them
The topic of the article is the engine oil ZMZ. On Yandex a month several thousand requests for this item. And how warmly boil passion on the forums, it is generally a corrida)). There are supporters of semi-synthetics, there are adepts synthetics, there are crusaders to the last droplet of the mind protecting the old good mineral water. Everyone has its own truth. I will try to summarize my knowledge and operating experience in this topic, in relation to this family of engines.
Selection of viscosity
For a start, let's see the manufacturer's recommendations. Oil viscosity 10-40, 5-40, 0-40. Probably everyone knows that the first figure indirectly indicates the "pumping" of the product at low temperatures. Pay attention to the second digit. She is the same everywhere. Nowhere is the viscosity of 5-30. In a nutshell, I will try to explain why.
ZMZ engines are very poorly crushed. The so-called "group method". That is, 100 blocks were brought from the boring, they were guaranteed to stand pistons and the engine must earn. This phenomenon wears in our plants a pederal name - "assembly warranty". Clearance in a pair of piston-cylinder on average should be 6 acres (0.06mm). Four weave is a clean gap and two or three weavers on Hon in the cylinder. The average digit on the engines of ZMZ is 10 acres. There were copies of up to 15 acres. What is the conversation? Oddly enough to viscosity oil.
Liquid oils for this engine may be simply detached. With such gaps, it simply will not stick to the "piston-cylinder" pair. Therefore, the plant and viscosity data are recommended. The plant just secured insurance.
Motor oil ZMZ, manufacturer selection
For many years, I have been using the products of the concern Elf-Total. There are several reasons. Starting with the fact that these are "clean manufacturers" and nothing is purchased on the side, ending with the online work. That is, if I need to clarify the details on a specific canister, I can make a request, and I will be sent to "Himanaliz" for this party "and its movement in the market. It is also possible to make a chemical analysis to work out, so that you can learn from the remaining products to learn about the wear of the engine, is the substitution interval and other utility sufficient. This pleasure is not cheap, but it's nice to feel behind such technical support. He asked about the similarity of different motorists and services working with other manufacturers. Nothing like this is offered and close.
Our country is immense, so the engine oil ZMZ must be for each climatic zone - its viscosity. For the middle band of our immense homeland, I prefer the viscosity of oil 10-40, for the northern regions of 5-40, for "resort places" 0-40. But be careful, very often I sent photos of the wet crankshaft crankshaft, so before using oils 0-40, it is better to change the cuffs, something more corporate than what the plant sets.
Of course, to tell and praise words for a very long time. I will give a specific example. I give a photo, the engine of my St. Petersburg client, which lils the ELF 10-40 oil, which I bring from the ditch, from the moment of buying a car. Mileage at the moment 90 thousand kilometers. Note that there is not a single varnish sediment and if the gasoline is washed off the oil film, then the GBC will look almost like new.
GBC ZMZ 409 after 90 thousand km
This photo was sent by me to the company manufacturer, that is, in Elf-Total. At first there was no answer, and then they called me, thanked and asked: how many people work with me in the company. Talked, I forgot about it, and a week later I was sent an indicated number of branded overalls. (I would know that no one would check out, would say that 100 people).
Motor oil ZMZ. Little cunning
Polytrafic 10W-40 oil It was suggested to me by ELF employees themselves. According to a very simple American classification, ZMZ engines fall into the category - Light truck. That is, light trucks, or otherwise, commercial transport. So, they can fill the oils of a commercial group. What does this mean, translated into Russian? This is an oil intended for commercial vehicles with large runs. Allows you to increase the interval from replacement to replace. In these oils double package additives. The disadvantage is only one: as they are used for truck engines, the manufacturer produces them in 20 liter canices. That is, this canister is enough for pouring to a gazelle or patriot by 3 times. Therefore, people have a question of storage. Otherwise, this is the best option that by price per liter of oil, which is by its characteristics. The viscosity of this oil is 10-40. Product name Polytrafic 10W-40. This product also has tolerance of almost all leading freight manufacturers, both for gasoline and for diesel engines.
The mass production of the engine of the Savolzhsky motor plant ZMZ 406 started in 1997, although the appearance of his first prototype was held four years earlier - in 1993. The 16-valve power supply with 4 cylinders was designed to complete the gas-3105 - promising at the time of the domestic model. Subsequently, the 406th engine was also established on Gazelle and Volga 3102 and 3110. For all the time the serial release, it was presented in 2 versions: carburetor (4063.10 and 4061.10) and injectory (4062.10). Over time, the carburetor version was removed from production, and only injector remained. This made it possible to reduce gasoline consumption and speed up the engine start. About what oil was flooded in the engine and how much will be told on.
ZMZ 406 became the first Russian unit in which the 4-valve design was envisaged, the electronic gasoline injection system and a 2-step chain drive. A simple and reliable cast-iron motor had excellent maintainability and served as the basis for developing more powerful engines with indexes 405, 409 and 514. The engine had a power from 110 to 145 hp. And with proper maintenance offered a rather large stock of the course - over 300 thousand km. Information about which oil and how much pouring into the motor will be further.
The peculiarities of the engine were high weight (cast iron heavier than aluminum), the use of a circuit hydraulic equipment, a reduced piston stroke (only 86mm), as well as a polycliner belt, which automatically excluded its cliff. Problem places ZMZ 406 were traditionally large oil consumption, poor quality of electronics and instruments, the complexity of the timing and its bulky, huge mechanical losses due to the use of powder metallurgy and unsuccessful solutions in the casting and processing of parts.
Engine ZMZ 4061.10 / 4062.10 / 4063.10 2.3 liters. 100, 110 and 145 hp
- What engine oil is poured from the plant (original): Synthetic 5W30
- Oil types (viscosity): 5W-30, 5W-40, 10W-30, 10W-40, 15W-40, 20W-40
- How many oil lithres in the engine (total volume): 5.4 liters.
- Oil consumption per 1000 km.: Up to 100 ml.
Engine ZMZ 406 2.3 l.
Engine Characteristics ZMZ-406
| Production | ZMZ. |
| Engine brand | ZMZ-406 |
| Years of release | 1997-2008 |
| Cylinder block material | cast iron |
| Supply system | injector / carburetor |
| A type | in line |
| Number of cylinders | 4 |
| Valves on cylinder | 4 |
| Piston stroke, mm | 86 |
| Cylinder diameter, mm | 92 |
| Compression ratio | 9.3
8* |
| Engine volume, ccmm | 2286 |
| Engine Power, L.S. / Ob. Min | 100/4500* 110/4500** 145/5200 |
| Torque, Nm / Ob.min | 177/3500* 186/3500** 201/4000 |
| Fuel | 92 76* |
| Environmental norms | Euro 3. |
| Engine weight, kg | 185* 185** 187 |
| Fuel consumption, l / 100 km - city - Rouss - 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 engine oil | 6 |
| When replacing pour, l | 5.4 |
| Replacing the oil is carried out, km | 7000 |
| Engine operating temperature, hail. | ~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. Gas Gazel GAZ Sable |
* - for the engine ZMZ 4061.10
** - for engine ZMZ 4063.10
Malfunctions and repair of the engine Volga / Gazelle ZMZ-406
The ZMZ-406 engine is the successor of the classic ZMZ-402, a completely new motor (albeit with a loaf on Saab B-234), in a new cast-iron block, with the upper arrangement of the camshafts, the latter is now two and, respectively, Motor 16 valve. At the 406th, hydrocomathers appeared and it does not threaten with constant adjustment of the valves. A chain is used in the GDM drive that requires a replacement of 100,000 km, in fact, walks more than 200 thousand., And sometimes it does not reach 100, therefore it is necessary to control the state of the chain, calm and hydraulicers, tensioners, usually, Very low quality.
Despite the fact that the motor is simple, without changing phases of gas distribution and other modern technologies, for gas, it is a big progress with respect to the 402th engine.
Engine modifications ZMZ 406
1. ZMZ 4061.10 - Carburetor engine, SJ 8 under 76th gasoline. Used on gazelles.
2. ZMZ 4062.10 - Injector motor. The main modification is used on the Volga and Gazelles.
3. ZMZ 4063.10 - Carburetor engine, SZh 9.3 under 92th gasoline. Used on gazelles.
Faults of engines ZMZ 406
1. Hydraulic chains of timing chain. It has a prison property, due to the absence of oscillations, there is noise chain, followed by the destruction of the shoe, jumping the chain, maybe even its destruction. In this case, ZMZ-406 has an advantage, it does not oppress the valve.
2. Overheating ZMZ-406. A non-separation problem is usually to blame the thermostat and a scored radiator, check the quantity of the coolant, if everything is in order, then look for air traffic jams in the cooling system.
3. High oil consumption. It is usually the case in the oil-circulation rings and valve glands. The second reason is the labyrinth oil reflector with rubber tubes for the oil, if there is a slot between the lid and the labyrinet plate, then the oil goes. The cover is removed, the sealant is missing and there is no problem.
4. Truck failures, uneven XX, all these are dying ignition coils. On ZMZ-406, this is a simple, change and the motor will fly.
5. Stage in the engine. Usually in the 406th, the hydrocompensators are knocking and they ask for a replacement, they go, approximately 50,000 km. If they are not, then mass options, from piston fingers, to pistons, connecting rod liners, etc., the autopsy will show.
6. Troit engine. See Candles, Coils, Measure Compression.
7. ZMZ 406 stalls. The case, most often, in the Wires, the crankshaft sensor or RXX, check.
In addition, sensors are constantly buggy, low-quality electronics, problems with fuel pump, etc. Despite this, ZMZ 406 is a giant step forward (compared to ZMZ-402 outdated design), the motor has become more modern, the resource will not go anywhere and still, with adequate service, timely replacing the oil and a calm driving manner, may exceed 300 thousand .km.
In 2000, the ZMZ-405 engine was developed on the basis of ZMZ-406, and 2.7 liter SMZ-409 appeared later, a separate one.
Engine tuning Volga / Gazelle ZMZ-406
Forcing ZMZ 406.
The first version of the increase in engine power, by tradition, atmospheric, and therefore we will put shafts. Let's start with the intake, we put the cold air fence, the receiver of a larger volume, we saw the cylinder head, we are modifying the combustion chambers, increase the diameter of the channels, grind, put the corresponding, lightweight T-shaped, valves, springs 21083 (for evil options from BMW), shafts (for example, OKB Engine 38/38). Turning a regular, tractor piston makes no sense, so we buy forged pistons, light connecting rods, lightweight crankshaft, balancing. Exhaust on a 63 mm pipe, straight-time and configure it all online. The output capacity is approximately 200 hp, and the motor nature will receive a brightly pronounced sports hue.
ZMZ-406 turbo. Compressor
If 200 hp For you, children's fun and want real fire, then paying this path. So that the motor normally tolerate high pressure, we put the enhanced wrought piston group for a low SJ ~ 8, the rest of the configuration is similar to the atmospheric option. Turbine Garrett 28, manifold under it, Pipings, intercooler, nozzles 630s, exhaust 76mm, DDA + DTV, tuning in January. At the exit we have about 300-350 hp
You can change the nozzles to more productive (from 800ss), put Garrett 35 and blow until the motor falls apart, so 400 and more hp can be blown out.
As for the compressor, everything is similar to the turbine, but instead of turbine, collectors, Pipes, Intercoulera, we put the compressor (for example, Eaton M90), customizable and go. The power of the compressor options is lower, but the motor is blistering and pulls from the bottom.
