406 Engine is mainly installed on cars manufactured by a gas plant. We already know that such a motor in carburetor performance is reliable and durable. Small and medium repairs can be held with your own hands. And what is the injection?

Advantages of 406 injection engine

With proper operation and timely, it is no less reliable. In addition, has a number of benefits:

• less harmful emissions in atmosphere;
• higher engine efficiency, as fuel is fed at the right time and in necessary quantityIn addition, part of it is not lost on the way from the gas tank to the cylinder;
• from the second point it follows that injector Motor. Consumes less gasoline (on average 11 liters per 100 km, against 13-15 on carburetor);
• it also follows the fact that the engine develops greater power (130 hp against 100 on the carburetor).
• do not float idle;
• no need, like a carburetor, periodically regulate the injector;
• in winter, you can immediately touch, not warming up the motor.

The only minus is to repair the injection system with your own hands without knowledge and special tools is almost impossible. Yes, and it is difficult to break the breakdown if not diagnostic equipment. And also spare parts for the injector more expensive than on the carburetor.

But repeat if you spend on time to be refueling qualitative gasoline And take care of the car, the injector will not take you trouble.

Is it possible to install gas-filled equipment?

Install HBO, it means to solve many tasks:

1. Cost of money - gas costs cheaper than gasoline.
2. Reducing the risk of detonation, since the gas is octane number above.
3. The best lubrication of rubbing parts in the cylinder - the gas does not wash off the oil film from the cylinder walls, unlike gasoline.

With such advantages, the installation of HBO per 406 engine (injector) does not always justify itself. And all due to features: GBO installation involves the installation of a gas dosing system. And they all have a carburetor type.

That is, consuming gas, the engine will work like a carburetor. The system will not be able to also correctly, as in the case of gasoline, carry out the dosage of fuel on certain modes of operation of the motor.

And now we will tell you:

• about the most common problems of 406 engine (injector);
• and how to get rid of them.

Problems with injection 406-M engine and their solution

1. The engine stopped starting immediately:

• it is necessary for a few seconds to turn the starter and put pressure on the gas pedal (although the motor is hot);
• as will start, gives large turns (about 2000 rpm) and a few seconds of Troit.
• the controller does not notify that the system has a malfunction.

In 90 cases of 100, a broken temperature sensor is to blame.

The fact is that when starting the engine, it says the controller that the engine is cold and it is required to warm it. The controller obediently reacts and switches to increased injection mode and high revolutions. In short, check the function of the sensor and replace if necessary.

2. The engine does not start:

• twist the starter, and the cylinders do not feel compression;
• check the candles, and they are wet.

Most likely the culprit of the tragedy chain timing: she either jumped up, or left the tags.

You need to check the chain:

• if it is in place, then set the tags;
• if she flew, then put, exposing the tags.

It may happen that after installing the chain, when you try to start the motor, it seems to be sneezing and again will stop starting.

To avoid this, after installing the chain by tags, without screwing the candles, start the motor. Make it until the oil pressure lamp will not go out. Now screw the candles and start real.

And finally: the solution to the problems described is better to trust the masters. If you do not have the appropriate skills, then at best you will do nothing, and at worst - the car will need more serious repairs.

Video about ZMZ 406

Comments:

Sasha

2013-06-18 13:16:39

Engine 406 Injector grabs and Emboss, and before that I rode, disappeared idle and burned check

vitaly

2013-06-26 18:18:02

The same problem. The driver is twist, but it does not start, what to do

sensor

2013-08-17 19:48:55

Air Sensor Check

serega

2013-10-30 08:00:03

The starter twists that good, it is bad. Akum is new, another makes no problem. The timing chain Motorist changed, candles flooded. I am a spark, the diagnostics said change the air sensor, changed - the same !! (

Yuri.

2013-11-15 08:54:52

I have a gear engine in a warm form, did not start warm, I drove only with a gas pedal, changed the sensor to the identity and everything worked as a watch.

Serega

2013-11-16 10:30:28

Guys is the disease of this engine

Denis

2013-12-18 01:04:21

I went to the store. I drove, turned on the neutral - the engine worked perfectly, then something shuffled and stalled. I tried to start - it does not turn, the tug will not start. What could be the reason?

Arthur

2014-01-12 15:23:38

Does not develop full capacity to gas, on gasoline - norm, why?

Oleg

2014-01-19 20:39:17

Gazelle 2009. 100-ku thrown out and put 406 injectors. The machine is tupit and gas consumption is about 22-25 liters. What is the problem?

yura

2014-01-31 15:51:25

I have a 406 carburetor, I want an injector to put

sanya

2014-02-02 17:11:35

What kind of oil is better to fill in the engine 406 injector?

Irina

2014-02-04 20:45:50

Made overhaul Engine 406 Ing. After the assembly made a cold run. Then installed on the car after running on cold pressure 2, after warming up the pressure drops to 0. Disassembled the engine we have: cerviced necks and beds. Tell me what's wrong?

dmitriy

2014-02-06 18:56:57

I worked 406 injector engine, gasoline ended. Left overnight, hit the frost. Brought gasoline, began to start, got the battery, charged, not start. Grabs, shoots the silencer. Checked the chain, tags in place, and not start. What to do?

Vladimir

2014-02-20 16:58:30

There was a problem, maybe someone came across, please answer.
Sable, 406 injector, starter twist, spark on the candle, gasoline arrives - does not start. From the pusher at once - by 5-10 meters.
Changed coils, candles and air filter, and the result is the same - only from the pusher. Tell me who came across or thought. Thank you.

Igor

2014-02-24 11:03:03

On the engine ZMZ406 changed the upper hydraulic chain. The car stopped starting. What is the problem?

sergey Efimov

2014-03-26 12:04:23

With difficulty starts with full gas, when the gas is reduced, the troit and stalls, charging on small revs does not work, what to do?

michael

2014-04-06 15:09:16

Guys, tell me what happened? The check is burning and the turnover itself raises, and if the gazan is thrown off long

lech

2014-05-23 17:23:49

It works on the cold perfectly, as it warms up to 90 degrees when turns stalls, and at idle works, what to do?

Andrew

2014-06-06 11:45:24

Guys, I have such a problem. Cashpins the pressure arrow even when the ignition is turned off

Vitya

2014-08-25 18:03:46

I have a Volga 105 with internal 250 injector, also encountered the same problem, without a gas pedal, it's not to start at all, on the cold with sin in half and troit, brutally smoke brings out of the pipe, warms up, stops going smoke, drown, try to start - not Mock. Gas in the floor, twist, it seems to be grabbing and immediately stalls, tell me what could be

Vadim.

2014-08-26 18:18:58

Please tell me! Volga 31105 406 does not start, put new candles, wires. There is no spark and candles dry. No gasoline to candles. What could be the reason?

anton

2014-09-15 05:43:32

I start, gas in the floor, cracking under the lid of the claps, the turnover will jump, the sausage of the engine, the check is burning, the lamp will be fucked at the temperature and pressure

Motorist

2014-10-19 21:32:08

Serega, the camps shafts he did not correctly put
Arthur30 percent of power loses on gas
Oleg, set shafts on the indicator expose
Yura, Believe Motorist, carb better even financially
Sanya, Zeke 10 in 40 or Esso 10 in 40
Dmitriy, water on the nozzles - in a warm place car
Igor, hit the labels on the camps
Michael, throttle valves on the injector
Vladimir, Camped shafts must be properly set on the indicator from the first cylinder

Peter

2014-10-27 08:14:05

Fuel swap relays and tachometer does not work

Sergey

2014-11-10 17:38:32

The engine is very badly gaining momentum, what could be the case?

Alexei

2014-11-24 20:42:09

On the cold start, it works well, it works and starts tall, sneezes, the engine jumps, and then stalls within 5 minutes, help what to do?

Denis

2014-11-28 16:04:22

Tell me, it's great on the cold, but how to heat up to 60, it loses momentum, you are developing on gas, it develops with difficulty, what could be the reason?

Alexander

2014-11-29 17:28:54

406 injector will not start. In the evening I put the car, and in the morning there was not a big frost. He twist, he twist, almost grabbed, but a skimulator, charged - in general it does not grab, the candles floods. Checked, the chain is not tames. I put up, changed the candles, wires, but in no way start. Coils workers. Help, I do not know what to do.

Artem

2014-12-10 14:40:11

Please tell me that behind the relay under the hood, over the motor is paired with fuses? Does not start, candles dry! Plug the cylinders, grabs and stalls again! Where are the injectors relays and their fuse? Thanks for the help!

Andrew

2014-12-14 13:53:52

It does not start, the engine floods the candles, there is a spark, but some weak.

sergey

2015-01-29 20:51:55

Please tell me what kind of compression should be and how to measure it correctly?

Sanya I.

2015-02-12 14:03:02

Tell me! In the morning I start, warming up, turns 1100, do not fall less. I changed everything, the diagnosis does not show anything, I remove the terminal everything is in order, the terminal is already tired of shooting, the injector.

sasha

2015-02-12 18:28:55

Problem, I'll get a car in the morning, I warm up the turnover of 1000-1100 Temperature 80, I remove the terminal and wear it in a couple of minutes, I'll get up - turns 860. What is it?

Dima

2015-03-10 18:28:07

Through the extender throws Tosol

Evgeny

2015-03-17 08:28:07

The engine 406 injector, overwhelms on the cold, when heated 47/50 degrees, everything comes to normal. Tell me what reason. The diagnosis was determined that everything is normal.

Aman

2015-03-17 18:51:18

And I have the same problem and now has become poorly started, at least earlier at 42 started

Dmitriy

2015-03-29 05:35:32

The engine grabs and not start (on the cold), everything is in order. After reading a bunch of forums, fascinating dozens of sites, allocated 3 main reasons: temperature sensor, fuel pressure regulator, and not tightness of nozzles
If this is a temperature sensor, you can try to disconnect the vacuum hose and, without squeezing the gas pedal, try to run D.V.S., if you start, the sensor is not working. Everything is more difficult if this is the pressure regulator of the fuel line, on one site found a diagnostic method, but without a stand, you can not even try.

Vitaly

2015-05-09 14:17:31

UAZ HANTER ZMZ 406, fuel system of norms, all for the diagnosis of norms, except for the fact that there is no discharge 0 in intake manifold, I can not find the cause, at idle it works exactly, when you press the gas as if there is no fuel, it does not develop the revolutions shoots !! Tell me which there may be more reasons except fuel system and compression, sensors are all the rules?

Subject

2015-07-01 23:42:55

UAZ Patriot restyling, engine 409 (406), only at a temperature of 40 degrees does not want to start the first time (start only after 4-5 times). The check does not burn, and the diagnosis does not show anything. Changed the coolant temperature sensor and did not help! What could be?

alexander

ZMZ-406 - line of row 4-cylinder 16-valve gasoline car engines internal combustion Production of OJSC Zavolzhsky Motor Plant. The ZMZ-406 engine was originally designed for installation on a promising model GAZ-3105. The first engine prototypes appeared in 1993, the beginning of a petrolery assembly in 1996, entering the main conveyor in 1997.

The engine was originally created under modern nutrition and ignition systems controlled by a microprocessor; Carburetor options appeared later (injector version - ZMZ-4062.10, carburetor - ZMZ-4061.10 and 4063.10). For the first time in the Russian engine station in the design of the ZMZ-406, it was applied: 4 valves for a cylinder, hydrotherapists, 2-step chain drive 2 camshafts, an electronic fuel injection control system and ignition.

Specifications

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	150 200+

* - for the engine ZMZ 4061.10
** - for engine ZMZ 4063.10

Modifications of the engine 3m3-406

• 3M3-4062.10 - Injector motor under gasoline AI-92. It has a compression ratio - 9.3. Power - 150 hp For passenger cars and minibuses GAZ 31054 Suite configuration; GAZ 3102 (1996 - 2008).
• 3M3-40621.10 - Modification of the engine 3M3-4062.10, corresponding to the Euro-2 environmental standard.
• 3m3-4063.10 - Carburetor version of the motor designed for light commercial trucks and minibuses GAZ 3302, 33023, 2705, 3221, 32213, 322132, 32214, 3234, Ruta, Bogdan and Dolphin. Reduced to 8 degree of compression under gasoline A-76. Power - 110 hp
• 3M3-4061.10 - Carburetor engine for light commercial vehicles GAZ 3302, 33023, 2705, 3221. Reduced to 8 degree of compression under gasoline A-76. Power - 100 hp

Common malfunctions and operation

• Most often, the owners complain about capricious carburetor versions;
• Low reliability has a timing chain (when the valve cliff does not oppress);
• Many problems deliver the ignition system, most often - coils;
• Hydrocompensators usually serve not more than 50,000 km, and then begin to knock;
• Mascarial rings are quickly located and the maslip begins.

The carburetor 406th motor is less economical due to the impossibility of precise gasoline feed adjustment. More accurately adjust the amount of fuel is almost impossible, which is reflected in the power indicators and fuel consumption.

The injector noticeably exceeds the carburetor analogue of reliability, efficiency and power. One of the main positive qualities of the injectors can noted the absence of the need to produce mandatory motor adjustments. The system is not subject to clogging here, there are no jets, fuel in accurate quantity goes directly into the cylinders.

Engines Models ZMZ-4061.10 and 4063.10 (view from left):
1 — drain plug; 2 - Oil Carter; 3 - exhaust manifold; 4 - Engine Support Bracket; 5 - Crane of the drain of the coolant; 6 - water pump; 7 - emergency temperature sensor coolant; 8 - Cooling fluid temperature sensor; 9 - engine temperature state sensor; 10 - thermostat case; 11 is an emergency oil pressure sensor; 12 - oil pressure indicator sensor; 13 - pointer (probe) oil level; 14 - ignition coil.

Engines Models ZMZ-4061.10 and 4063.10 (view right):
1 - synchronization disk; 2 - synchronization sensor; 3 - oil filter; 4 - starter; 5 - detonation sensor; 6 - Cooling fluid drain tube from heater; 7 - inlet tube; 8 - Hydraulic chain; 9 - generator; 10 - the generator belt; 11 - Pullets of the water pump; 12 - tensioning roller; 13 - gas station.
Transverse section ZMZ-4061.10 and 4063.10:
1 - Oil Carter; 2 - oil pump receiver; 3 - oil pump; 4 - Oil pump drive; 5 - the gear of the intermediate shaft; 6 - block of cylinders; 7 - inlet tube; 8 - ventilation nozzles; nine - camshaft inlet valves; 10 - inlet valve; 11 - valve cover; 12 - distribution shaft of exhaust valves; 13 - pointer (probe) oil level; 14 - valve hydroeter; 15 - external valve spring; 16 - valve guide sleeve; 17 - exhaust valve; 18 - head block of cylinders; 19 - graduation collector; 20 - piston; 21 - piston finger; 22 - rod; 23 - crankshaft; 24 - connecting rod; 25 - indigenous bearing cover; 26 - drain plug; 27 - the housing of the pusher; 28 - guide sleeve; 29 - compensator case; 30 - lock ring; 31 - the piston of the compensator; 32 - ball valve; 33 - Spring Ball Valve; 34 - Ball valve case; 35 - Scroll Spring.

The question of which carburetor is better to put on the Gazelle with 406 engine can often be heard from the owners this car. Most popular russian cars The middle class produced by the Gorky plant has a wide degree of unification. On the 406th Gazelle engine, you can install carburetors: Solex, Weber ,. To pick up the most efficient carburetor for gazelle with carburetor Engine, It should be studied all their pros and cons.

We put carburetor Solex on Gazelle with 406 engine

Carburetor Solex is produced by LLC Dimitrovgrad Avtokomponent Plant LLC under license from Solex, France. And this carburetor without problems can be installed on the gazelle with the 406th engine. The general view of the carburetor is shown in Fig. 1 below.

Fig. 1. Carburetor Solex.

For many years of operation on cars, Gazelle devices such as Solex showed themselves as reliable, durable, convenient mechanisms. In the most critical conditions, frost -40 degrees, a blizzard, a blizzard of 406 engines are brewed after night parking on the street and carry around the clock watch on all highways of Russia.

The Carburetor Solex on Gazelles with the 406th engine does not fail in the conditions of highlands with a rarefied air, nor in the sands of Central Asia, nor in the extreme north. All carburetor systems are steadily functioning both on the depleted and on a highly enriched mixture when overflow fuel.

Settings are highly dependent on the fuel level in the float chamber and adjustment idle move. The first adjustment requires a lot of patience. At the factory, the fuel level is regulated by a template with a test float. Under the conditions of the garage, the operation is carried out with repeated screwing and twisting the quality screw, as well as the bending of the edges of the float.

Instructions for adjusting the carburetor Solex on Gazelle

ATTENTION!The feed hose is removed on the heating engine. Caution! Can sprinkle gasoline! Unscrewed and removed the lid float Camera Together with floats. Measure the distance from the selex carburetor cover to the fuel surface in two chambers. Better to make a caliper. The perfect distance for the proper operation of all systems is 25-35 mm.

Adjustment is carried out by sweetening the edges of floats. It is necessary to merge from float chambers. After the end of the adjustment, you must start the motor and fill the chambers with gasoline to the designated level. The next adjustment refers to the idle engine.

Heat the engine up to 90 ° and drown out. Tighten the screw 11 shown in Fig. 1, until it stops. Turn the engine, the sublicas must be removed, and the air damper (Fig. 1 number in Figure 4) Open. Unscrew the quality of the mixture quality, to achieve stable engine operation when the accelerator pedal is released. Turns should not exceed the value of 1200 rpm.

Screw the screw until the engine starts to twitch, work with interruptions. Unscrew to 1-2 turn back. Motor began to work like a clock. Thinner settings are made at their discretion. According to the engine speed, the engine should be within 800-900 rpm.

Pros and cons Setting the carburetor DAAZ 4178 on Gazelle

Arguing, what kind of carburetor is better to put on a gazelle with a 406 engine, it is necessary to consider another of the most compact and reliable Russian carburetors. Such is domestic. The device is shown in Fig, 2 at the bottom.

Fig. 2. Carburetor 4178.

The 4178 carburetor is not much different from the previously represented carburetor. All systems are practically identical, adjustments are similar. Both carburetors are made by the same enterprise. Here carburetors are made for the entire domestic car industry: VAZ, GAZ, IZH, Moskvich, UAZ.

Carburetor DAAZ 4178-1107010 is a more complex device than carburetor Solex. This is a two-chamber emulsion type mechanism, whose throttle valves are opened sequentially.

Float chamber Balanced, systems are sequentially located:

• suction gases;
• nozzles of selection of the control vacuum in the throttle housing;
• recycling system of exhaust gases.

IMPORTANT!Balanced, high-quality mixing of the components of the air-fuel mixture is achieved by the ideal design of the diffuse channel with the air swirl located in it. Innovative development of Dimitrovgrad scientists - the accelerator pump made it possible to carry out the most smooth transition during a sharp opening of throttle dampers.

Thanks to the improved design, the carburetor quickly gained the popularity of gazelle drivers. Many motorists reappear their gazelles by this carburetor and do not regret. The main characteristics and consumption of fuel in carburetors Solex and DAAZ 4178 are the same.

When among the owners of Gazelle, it comes to what the carburetor is better to put 406 engine, many come to one of the options, namely to the installation of a long-tested carburetor K-151D. This carburetor is very popular and is often found in UAZ, IL, Volga, Sobol. For 406 engines, the Gazelles developed a modification K-151D.

Fig. 3. Carburetor K-151: 1 -Vinth-tube axis float; 2-cards on the axis of the air damper; 3 - Threaded tube fuel gibber transition system secondary chamber; 4 - Spreads in the vacuum regulator of the ignition distributor; 5 - decor selection unit to the valve of the EPHX system; 6 - Carter ventilation system fitting; 7 - housing fuel filter with supply and bypasic fittings; 8 - screw fastening of the filter case; 9 vacuum control of the exhaust gas recirculation valve valve: 10-protection plug of emulsion jibera of the idle system; 11-plug fastening housing air filter: 12 - threaded plug of fuel drain from the float chamber; 13-passer supply of pouring to the EPHX valve; 14 - screw adjustment of the composition of the mixture at idle (screw "quality"); 15 and 22 - microswitch EPHX system; 17 - Rotation Frequency Adjustment Screw crankshaft At idle (screw "quantity"): 18 - screw of the two-beam lever of the starting device; 19 - trigger lever; 20-perch on the axis of the air damper; 21-type air damper drive; 23 Spring free stroke of throttle control lever; 24 - overhead lever control cam control device; 25 - adjusting screw of the air damper drive thrust position; 26-Operating Mustache Lever throttle valve second chamber; 27 -Worving a muster throttle lever of the second chamber; 28 - launching device cam; 29 - screw-stop lever flap of the second chamber; 30 -Tellifaceous fitting: 31 - screw filling fist of the accelerator pump (version of the execution):

When autogas translated the production of gazelles to the installation of 406 engines, at the same time the K-151D carburetor was upgraded. Since then, the mechanism is successfully used in gazelles. Structurally, the unit is similar to Carburetor Solex. It is distinguished by the presence of a suspension in the form of a wire, synchronizing the simultaneous movement of the crescent device of the launch device and the throttle heel.

IMPORTANT!Thanks to this wire, adhesion is created between two separate mechanisms. S suberos guarantees fast, easy engine start. SUPPLC can be adjusted by setting up the necessary values. Engine start parameters are exhibited, depending on the outdoor air temperature and weather conditions.

Other carburetors that can be put on the gazelle

Answering the question: Which carburetor is better to put on a gazelle with a carburetor engine of the 406th model, it can be said that the stable, reliable, long-term operation above the engine mentioned is also possible when these machines are configured by carburetors Weber models, ozone, K-131.

However, their installation involves a minor re-equipment of electronic systems and control blocks. In the factory conditions, the package of gazelles said carburetors is not performed.

Pros and cons of carburetors

Engines modern cars for the most part, equipped electronic systems fuel injection - injector injection, Monovpromsk, Central Injection, Distributed Injection. The listed systems work perfectly, save fuel, but have a too high price. The second minus - when it fails or clogging data blocks, their repairs can only be performed under car service conditions on special stands. For it will have to pay a lot.

Carburators have many advantages: inexpensive, simple mechanisms. With proper adjustment, they bring significant fuel savings. The most economical is the K-151D carburetor - 8 liters of gasoline AI-92. The second in the amount of fuel consumption is Solex - 8.5 liters of gasoline AI-92.

The most voracious - carburetor 4178 - 9 liters of gasoline AI-92. Measurements were carried out on the highway at a speed of 90 km / h. Cons of carburetors: problems with cold start at negative temperatures at Solex models, 4178. Sometimes there are failures of the gas pedal, depletion of the fuel mixture.

These disadvantages disappear with proper adjustment. So on the question: what carburetor is better to put on 406 engine Gazelle, you can answer with full confidence: all three carburetors - Solex, 4178, K-151D are quite working mechanisms and can be installed on their gazelle. Proper adjustments Turn your gazelle in the beast. You will become a hero of all freeway.

Nor nail or rod!

Today, the most mass engines for Gazelle are ZMZ-406 with a working capacity of 2.3 liters, which since 1996 began to gradually displace the Motors ZMZ-402. Back in 1992, a small series was opened at the Savolzhsky Motor Plant, in which the pilot production of the engines of the new family of ZMZ-406 was organized. And the first sketches were made by constructors when approving the USSR Ministry of Automobile Industry existing then. The thought, the fracturing brain of many operationals since 1970 - "Why is it not possible to make a big" Zhigulevsky "motor for" Volga "and Raffi?" - got its embodiment in cast iron and aluminum. Although, of course, with a detailed consideration of the common between them, there is nothing, ZMZ-406, rather, simply similar to any good gasoline engine of that time. And not strongly outdated today. It became the first electronically controlled injection (injector) engine of this class, and even with a 16-valve two-walled head. How the curiosity today remembers the story with an overpriced to 150 liters. from. Volga motors capacity (how much money was overpowering for taxes ...), but in general the engine turned out to be very frisky. On the Nizhny Novgorod half-timer for a long time We installed only the carburetor versions of ZMZ-4061.10 and ZMZ-4063.10, developing 100 and 110 horsepower, respectively.

Contrary to expectations, the motor has retained the traditional maintainability of the ZMZ engines. The crankshaft is polished in three sizes after 0.25 mm, the cylinder block can be cleaned twice with an increase of 0.5 millimeters. The cast-iron unit is not so sensitive to the "Painted" antifreeze, as an aluminum in the ZMZ-402, and the absence of the sleeves only added stiffness and eliminated possible refrigeration fluid leaks. SCM specialists managed to disorderly assume the development of trends with the repair of engines that have been repaired at the beginning of the 90s. As in the water, the Motor ZMZ with boring in the last size unit usually stands to the Gazelle, moving on its own move to the scrap metal. Everything on it is already worn out, no one needs to be for nothing, but the engine is still alive.

Oil fasting ZMZ-406

Like all modern motorsThe ZMZ-406 family turned out to be very demandless to the quality of the oil used. Unfortunately, many carriers neglected the recommendations of the plant. After all, the "406th" motor is more arrogant in the oil menu than the ZMZ-402, which was content with a standard group of oils with the code API SE and SF, or in our operational properties group "G", such as M10Gi, M12GH, M5Z / 10G. Perhaps, with more frequent periodicity of the replacement of oils of this quality group, it would be enough, but it should be remembered that in the late 90s it was full-possible low-quality fuel in the market. So "oil pirates" contributed to the creation of a negative image of the ZMZ-406 engine.

When changing the brand of oil and the manufacturer, and even more so when switching to oil another base, viscosity or quality, it is desirable to wash the engine lubrication system. However, the ZMZ-406 engine under the valve lid, near the valves and in the oil channels of the block head remains approximately 300-350 g of oil. Half from this quantity can be removed, turning the plug in the head near the pressure sensors. When switching to synthetics, together with costs, runs up to the next replacement to 15-20 thousand km, which compensates slightly. Well, numerous additives to the oils are better not to use, but rely on the quality of the main oil. It contains all the necessary additives for durable engine operation.

For a new family, in the design of which applied valves and hydrothetakers of the timing chains of the timing chains, it is recommended to use improved quality oils with SG, SG, SJ code and do not save on the oil filter. After all, the particles of metal or deposits, falling into narrow channels or gaps between the conjugate details less than half a million, are blocked by gentle hydraulic devices. The failure of one or more valve hydrothels is immediately noticeable by characteristic and frequent knock under the valve lid. Of course, this knock will not lead to immediate and greater destruction, but it should not drive for a long time with such a malfunction. After all, the empty hydrotherapler will not fully open its valve, and therefore the engine will lose power. In addition, unnecessary shock loads on the camshaft camshaft also do not add. To eliminate knocks, it is necessary to replace the hydrocomathers, and this pleasure is not cheap. Those carriers that have not saved on the oil poured semi-synthetic or the synthetics of the desired quality, the grief did not know with new motors, especially if it was lucky with the quality of the hydraulic fighters and hydrocomathers themselves.

Step and resource ZMZ-406 chain

Alas, hasty launch in the production of this motor did not give it the best on his quality and resource. Of course, there were also separate copies of engines that raided 200 thousand kilometers and more, but mostly problems arose much earlier. At that time, the Achilles fifth of a new perspective motor turned out to be a precision plunger pair of hydraulic equipment of the timing chain chain. They are in ZMZ-406 two, everyone works on their chain. For those tensioners who walked to the conveyor ZMZ, it turned out to be overly great movement of the pusher to the next fixation. It was almost three millimeters, and pollution or insufficient accuracy of the processing of precision steam led to the hydraulic casing. It was not provided to the necessary degree damping the oscillations of the slave branch of the chain. The shock loads increase, which caused premature wear of the parts of the stretching device and the plastic shoe. If the driver did not pay attention to the noise, almost a rumble of the chain, and continued the movement, then the shoe was destroyed. And there, as lucky. At best, the chain rushed along the tooths of stars, the gas distribution phases were shot down, and the motor stopped. It is good that the designers took care to make samples in the pistons for the valve plates - they did not get them. In this case, the repair has boiled down to restore the installation of the phases and replacement or "recharging" of the hydroletlayer. If the chain fell, then the front aluminum lid was often deformed, and it was necessary to buy it. Because of such little things, flights were broken, the car on a day or two rose to the fence. The most discerning - breakdowns arose on a relatively young motor, with mileage of just 30-40 thousand kilometers. Often the installation of a new hydroletlayer gave only a temporary result, then everything repeated again. The craftsmen even began to adapt to the ZMZ406 engines of the collet spring tensioners from the VAZ-2101 motor - adjust the tension of the chains once every 15-20 thousand kilometers of special work was not. Even further went to the Moscow company Seth, its designers at the end of the 90s developed their own option and installed on the Zavolzhsky motor tension star instead of a plastic shoe. Such a scheme was used on the Ufa motors "Moskvich-412", and in the 1980s, athletes put an asterisk to the Zhiguli engine. In the past five years, the position with the hydraulic puments has changed for the better. There were alternative manufacturers of this node, there are already several varieties. It is known six main designs of hydraulic fighters for ZMZ-406, and everything is recruited over one and a half dozens of options, even gas filled. In 2004, the Zavolzhsky plant abandoned the use of plastic shoes of tensioners, the place was taken by asterisks. It turned out quite reliably, although they are made somewhat casually - the bearing of the asterisks with a large backlash, and its bracket, as if shifted manually.

OPINION

Konstantin Rukhaniexecutive Director of OJSC ZMZ - In 2008 - 2009 We are planning to hold the R & D complex and techno logical preparation of production aimed at further modernization gasoline engines The ZMZ-405 family and ZMZ-409, first of all, in order to fulfill them the norms of Euro-4. As you know, they are introduced in Russia from January 1, 2010. Since July 2007, exploited work on diesel engines ZMZ 514.32 is conducted. To fulfill Euro-3 norms, Ivro-4, we equipped these motors electronically controlled fuel equipmentCommon Rail manufactured by Bosch. By August, September 2008, it was planning to create prototypes of the gasoline engines of the Euro-4 diesel engines and proceed to conduct tests. For the implementation of R & D on all engine, it is planned to invest about 130-150 million rubles. During 2009, preparation will be prepared for the release of these engines.

Family

In general, in comparison with the engine ZMZ-402, a "four-plate" more compact motor, with the inter-cylinder distance, the diameter of the crankshaft neck and the piston finger have become less, but at the same time they did not lose in the resource. The ZMZ-406 engine became a source for other families of the family, while maintaining the unification of the design and technology. In particular, all ZMZ-406, 405 and 409 engines are the same elevation of the block from the crankshaft axis to the plane of the connector with the head, the same connecting rods, and the difference in the radius of the crank is compensated by a change in the distance from the piston pin to the bottom of the piston. For "Gazelle", the main advantage of the ZMZ-405 and ZMZ-409 engines with a working volume of 2.5 and 2.7 liters - greater torque: 215.8 N.Mm and 235.4 NM at 4000 rpm. In comparison with the ancient ZMZ-402, it is more than 23 percent. But only ZMZ-405 engines installed on Gazelles, more powerful ZMZ-409 for the totality of the reasons for the Gorky Automobile Plant do not supply. Installation on "Volga" and "Gazelle" chrysler engines Brazilian assembly is a partial alternative to ZMZ motors.

Improving the resource ZMZ-406: new trends

From January 2008, the release of the ZMZ-406 engines was stopped, although they will still be operated on the already released cars, and the motors corresponding to the norms of Euro-3 come from the assembly conveyor. These are injection modifications of ZMZ4052.10 and ZMZ-4092.10. Carburetor versions are released only for secondary market and on request for configuration of export deliveries to those countries where environmental requirements Less tough. For operation in Russia, only the 405th engine is installed on "Gazelle". Moreover, in addition to the fuel injection system, the engines have undergone a number of significant changes aimed at increasing the resource.

The old block of ZMZ-405 is easy to learn about the transverse slots of about 2 millimeters between the cylinders at the surface of the connector with the head. These ductures in the cooling system shirt improved the heat sink from the cylinder walls, but at the same time they reduced the rigidity of the upper part of the block. Even when tightening the bolts of fastening the head of the block, the required torque of the cylinder walls are somewhat deformed. If they were tightened "on the eyes", and even a good knocker, then the deformations increased. The changes in geometry affected the resource and at an increase in the oil consumption on the avgar. On the ZMZ-406 engine, such deformations were not observed, because the inter-cylinder jumpers of the 406th block, in comparison with the ZMZ-405, thicker: 14 mm against 10.5 mm.

To eliminate deformations, the new block of ZMZ-405 was made by 24 mm longer than the threaded part under the head bolts, and the inter-cylinder ducts were hidden in the depth of the unit. You can only see them in the context.

The head of the block with the introduction of Euro-3 norms was also upgraded. With the use of electronically controlled choke, the need for the channels of the idling system and the heating hoses of the throttle assembly coolant was disappeared. So the old head on new block Cylinders cannot be installed. Moreover, the former blocking of the head of the block from the baldas missing material was changed by the metallic, import company Erling Klinger. It is two-layer, similar to those used on modern passenger diesel engines, at a smaller moment of tightening bolts ensures a reliable seal of gas joints, as well as channels of lubrication and cooling systems. The thickness of the new gasket is almost a millimeter less than the old to compensate for this size, the pistons took half a million below.

It is no secret that domestic engines from many foreign cars are different increased flow Oil. Of course, on eating oil, the Motor ZMZ-406 does not go to any comparison with ZMZ402. That was really voracious. ONLY ONLY ONLY DANGE OF THE REAR NIGHT BEARING - Dan Ford Traditions, has been drinking operational places from 1932. The crankshaft on the ZMZ-406 immediately condensed with cuffs, and the front stands from the outside of the cover - if necessary, replaced it will not be difficult. Contrary to the expectations of pessimists, they keep oil, do not let it into the combustion chamber valve stem seals valves. They are unified with "Zhigulevsky", for more than 30 years, they seem to have learned to do - do not dub, as before. Modern piston rings Also contribute to the cause of reducing oil consumption, recently they put Czech production of the Ring of the company Buzuluk. Save them safely and prevent the detonation sensor on the pistons to destroy the detonation sensor - adjusts the ignition installation. Although our OPERATORS and do not like electronics and especially do not trust ours, but still there is a lot from it.

And yet there is no limits to perfection. Now, to reduce oil consumption at the Ugra, the plant has changed the technology and parameters of the honing of cylinders. In order for the motor to do not sweat at the junctions compacted by gaskets, imported imported. The crankcase pallet laying, previously made from the rubber banding mixture, was replaced by metal, Erling Klinger with elastomeric sealing contour and T-shaped joints in places of pairing with the front lid and the gland holder. If during the repair of the engine of the new gasket will not be on sale, you can put the gasket of the old sample, they are interchangeable. The front engine cover was seriously changed,

from above, the fasteners were added with two more holes for a more dense contact with the head of the block. In addition, on the lid, they made a platform for the installation of an automatic tensioner of the polycliner belt of the attached equipment. Its resource should be about 150 thousand kilometers. Such a tensioner has long been time to do - due to the unsuccessful design of the old roller on the replacement of the belt, it was necessary to spend three hours. The difficulty of replacement, contrary to expectations, was not compensated by the belt resource. Imported serve about 40-50 thousand km, domestic less - from 10 to 30 thousand kilometers. Strong wear Observed B. winter time - transverse cracks appear due to temperature drops. If the belt begins to shake the skeleton thread, it hurts the crankshaft position sensor, and with large turns it simply knocks on it. And here as lucky: or the wires will break to the sensor, or refuses the sensor itself. In any case, the operation of the ignition system is stopped, and the motor stalls. The length of the polyclinic belt has changed with the installation of the new roller, with the engine without a hydraulic power pump, it was 1220 mm, and it became 1275 millimeters long. On motors with hydraulic lines, the belt has grown to 1413 mm.

Be that as it may, but the current Motors of ZMZ for "Gazelle" are the very "tity" in the hands of the carrier, which is undoubtedly better than any "crane".

Of course, the slowness with which the engines got rid of childhood diseases, typically Russian, but, pay attention, factory flaws are not so much, and the number positive feedback Operationals about these motors are growing steadily. Mileage in 300-400 thousand kilometers without overhaul ceases to surprise, and after all, these engines already in years, they only slightly touched up modernization. Those that the lightest should be even stronger. There is no reason to complain about the lack of spare parts - there are any and in each trading point. Gas and ZMZ never previously cared for their quality, and the fight against counterfeit is not conducted in words, but in fact (see "Flight" No. 3 for 2008 "Left Bliss"). And despite the fact that the requirements for dealers are tightened, the network service centers Growing and grows.

OPINION

Eduard Bogomolovthe head of the department of industrial equipment "Avtolan", Moscow - now Gazel's buses with new engines "ZMZ-405" on the enterprise are not at all, therefore there are almost no information on them. What can not be said about his predecessor 406th Motor - minibuses with such engines we have plenty. Unfortunately, it is difficult to make some comparison with others power plants. Yes, there are diesel engines, but there are not much released at all, and we did not buy such "gazelles", fundamentally working with gasoline, especially since they have proven themselves very worthy. After all, it is often to repair them worth dozens of times cheaper than, for example, Ford engines, and in terms of time, too, it turns out faster. And their resources in our conditions are comparable and amount to about 300 thousand kilometers. Although, according to official statements by Ford, the minimum mileage of their unit should be from 350 thousand kilometers. And repaired failed imported engine Will not every mechanic, despite the fact that ZMZ-406 has long been learned to repair in any workshop.

Spiral evolution

In 2005, the Ulyanovsky Motor Plant (UMN) entered the "GAZ Group" and continues to produce engines for UAZ and Gazelles. Own engineering in the conditions of tough competition allowed the "gas group" to gain some independence from suppliers and get additional profits. Motors are shipped not only on assembly line Gas, but also go to spare parts, and this is a very capacious market. Note that the goals on the conveyor of the Gorky Automobile Plant Motors ZMZ engines UMZ are not persecuted. This year it is planned to release only 20,000 engines for "Gazelles", about 10% of the need, and they only complement the existing set of power units.

Motors Umz: Epoch 92x92

Of all those installed on "Gazelle" engines at Ulyanovsky UMPS421 the longest life. On the basis of the Volga's Motor M-21, which was put on the conveyor back in 1956. Of course, during this time it was upgraded several times, but still the inter-Cylinder distances near the block, the diameters of the indigenous and connecting skeins remain unchanged. And by and large: connecting rods, distribution and crankshaft, the pallet of the oil crankcase, and an externally block does not confuse with any other motor. And it all started at the end of the 60s, early 70s from the release of "loaf" and "headstands" UAZ-451 and UAZ-452, as well as all-terrain vehicles of UAZ-469, were initially installed in its pure form a Volgovsky motor. They have from the loads associated with the road dripping road, as well as from a considerable mass of the gearbox and dispensing collected together, cracked and flew in half the carter of the flywheel. Several ventilation holes served as stress concentrators, and how to upgrade the crankcase, peeped on the ZMZ-24 engine. At the same time, instead of the filters of coarse and fine oil purification, ("pan" with a cardboard interchangeable element connected with a block of frequently discovered hoses), put a full-power oil filter from Zhiguli. It immediately increased the resource of the engine, and such a solution turned out to be more successful than even on the ZMZ-24, although the further modernization was led to the Lentally on the Savolzhsky Motor Plant. Then they were not yet competitors. Changing the crankshaft - the indigenous liners have become the same width, and their covers are cast-iron, with the skirts of the pistons removed the thermo-componence slot, entered the crankcase ventilation system, made collectors "round" in cross section. The next modernization occurred in the late 80s, at the beginning of the 90s, the engine received the designation UMP-417. By this time, the ZMZ-402 engines were moved to the production of ZMZ-402 engines, and the head of the ZMZ-24 block went to Ulyanovtsy, it became possible to put two-chamber carburetors, the power increased. Installed an oil pump of increased performance, with a large diameter of gears - in all modes it became more stable oil pressure. Thanks to this, the "advanced" repairmen ceased to fit the nut under the spring of the reduction valve, the motor was less sensitive to wear in the pair of shafts.

All this time, the Ulyanovsky motor transferred several outdated design solutions and technologies of ZMZ, and he lagged in modernization. But on the engine UMP-417, Ulyanovsk designers still overtook colleagues mentors, given the low quality of our RTI, they carried out front gland The crankshaft on the outer side of the lid.

Motor UMW-421: end packing

In the mid-90s, Motor UMW-421 was put on the conveyor in Ulyanovsk. On him, on the joy of operationals, already instead of asbestos cord, there was a gland, and on the back pinch of the crankshaft for the sake of this changed the fastening of the flywheel. From the point of view of the plant, the main event was the use of pistons increased to 100 mm diameter, they went to increase the power and torque. Compared with 2.5-liter engines, the moment has grown from 170 to 220 N.m, and the power is from 90 to 115 horsepower.

In the Volga region, by this time, 16-valve Motors ZMZ-406 were already produced, there were nothing to the Ulyanovans, they have not fallen, then they remembered that on the distant Radio, the GAZ-M21 engine for the KGB was installed "Tchaikovskaya" piston with "weaving" in diameter. But the blocks in those times were cast in "Earth" and aluminum did not regret - the walls were very thick, in addition, the sleeve was installed on the top and bottom belt. The unit remained rigid even with increased size sleeves. And the current casting is not a couple of still - aluminum in deficiency, because on the UAZ-421 they decided to abandon replacement sleeves and pour them into the block forever. That is, they created a new block of cylinders. It would seem that it would seem a convenient case to abandon the ancient and capricious pallet of the oil crankcase with four pads, lower the connector below the crankshaft axis. Make a block tougher and reduce the likelihood of oil leaks. But no, everything remains straight. Another miscalculation was revealed during the operation of new engines when the time came to clean the sleeves. Not on each machine turned out to be "trunk" of the desired length, if it was not enough, and the move was insufficient - it had to unscrew the headed heads. On old motors with replaceable sleeves, they never did. It was not always possible to hardly screw them back after repair, when the head was tightened, one or two were often served from the block. I had to remove the head, cut into an enlarged thread in the block - if you managed to find testers of such a length! But it was possible to fill in aluminum ten long steel bedding nuts and secure the head bolts. Another problem was related to the fact that in the area of \u200b\u200bthe gas joint of the block and heads due to the characteristics of the fill of the sleeves on top of their boil was the layer of aluminum alloy block. It fanned during the operation of the engine, even with a small detailed ringing, is known than the diameter of the piston, the higher the tendency to the detament. So far, UMZ-421 was established only on UAZ, and even performed by the "under 76th gasoline", the misunderstanding. What are the runs on all-terrains ... The most serious tests were waiting for the engine after since 1998 it began to establish it for some modifications of "Gazelles". It was one to another: an increased load, large runs And urban traffic jams that cause engine overheating. As a result, the imaging of the motor in carriers was significantly undermined.

At the same time, everyone recognized that he was just a locomotive thrust with revolutions a little more idle. This is the indisputable dignity of Motors Umz. On these engines, as opposed to the Zavolzhsky, a large-diameter flywheel is still applied, which allows you to place a clutch that can transmit a higher torque. A good moment characteristic plays a primary role for a truck motor. The clutch basket leading its pedigree from GAZ-51 is rigid, with peripheral springs and forever chatting legs, has long gone to a modern with a petal diaphragm spring. Now most often put a basket of the German company "LUK", according to most carriers, it goes better than others.

There was no case that the operators complain about the drive of the timing gears and wander around the chains, and even more so on the gear belt. The gears are enough for 300-400 thousand kilometers, cases of breakdowns can be counted on the fingers - why look for them an alternative. Usually the first, and even the second overhaul on the ZMZ-402 engines and UMP-417 were made without replacing the camshaft, pushers and gear glasses. The only problem encountered in the Timing drive on Ulyanovsk engines and previously inherent ZMZ-402 engines - breakdown of the axis of the rumor with weakened fastening studs, breaking the shallow thread in the adjusting screw, stopping the lubricant to the upper tip of the rod. Slightly changing the design, all this can be eliminated.

OPINION

Igor Ganingeneral Director of Green-eyed Taxi LLC, Togliatti - In 2004, we purchased ten "Gazelles" with the engines of UMW-4215, but they showed themselves extremely unreliable. So, due to the destruction of the pistons, the cylinder block was punched on two engines. It is impossible to write off this on gas fuel, since the "fist of friendship" showed a motor operating on gasoline. In order not to endure losses due to transportation of the transport, it was decided to replace Ulyanovsk engines at the ZMZ402 tested time. Now on the balance of our auto industry is "Gazelles", equipped only with Motors ZMZ-405 and ZMZ-406.

Wind of change

And the thrust for the modernization of engines at the plant appears, but not in their will - competition between producers of light trucks is now rigid. "The GAZ group, where since 2005 it includes UMS, not only" Europeans ", Koreans and the Chinese with diesel engines are pressed (there is no dispute, in varying degrees), compatriots also do not guarantee that calmness that was before. Severstal Auto is going to seriously press the "Gazelle" in the market Fiat Ducato. and low-tonnage Isuzu collected in Elabuga and Semenov Nizhny Novgorod region Iveco Daily's release (see "Flight" No. 2 for 2008 "New Well" Selflor ").

Russia's transition to the norms of Euro-3 demanded a refusal to the carburetors in the power system of Ulyanovsk motors, the use of electron-controlled fuel injection. The plant is completed with the engines of the UMP-4216 fuel equipment of the company Bosch, and, according to specialists, they are causing even promising Euro-4. After upgrading the Gazelle's nutrition system with UMP-4216 motors, the flow rate is 14-16 liters per 100 km during operation in mixed mode, against 16-18 liters in the former carburetor modification UMPS-4215. The maximum power of the engine intended for installation on the "Gazelle" is 125 liters. with., And torque - 240 NM, which has a positive effect on the dynamics of a loaded car. In parallel with the improvement of environmental performance, work was carried out to improve the reliability of the engines, the quality of the assembly and an increase in the resource. In the direction of force aggregates, Experts of the British company Ultra Motive helped engineers. Together with the modernization of the engine UMW-421, work is underway on the refinement of design and technologies for setting in the future to the conveyor of the new Udeal 16-valve engine UMP 249 with an aluminum unit and maintaining a working volume of 2.89 liters. His release of Ulyanovsky is planning to start in 2010.

OPINION

Evgeny Berezin The chief designer of the Ulyanovsk Motor Plant - Motors UMP 4216 (Euro-3), tested in 2006, differ from Euro-2 engines to diagnose the crankshaft position and ignition passage. This was achieved thanks to the new design of the crankshaft damper with a tough bond between crankshaft and sync disk. In the system of control instead of an unreliable mass flow sensor, an absolute air pressure sensor with a temperature sensor is used. This made it possible to simplify the accounting of the air entering the engine, including in the event of a tightness impairment. inlet system. Cast-iron sleeves of modernized motors are now removed to the upper plane of the cylinder block connector, which ensured the tightness of the combustion chamber on the engineered plant declared by the plant (250 thousand km). Motors released until the end of 2007, the top edge of the sleeve was below the plane of the cylinder block connector and the GBC. Such a technical solution was dictated by the processing technology of the plane - the cutting tool works better on homogeneous material. However, the operation revealed that the gases penetrated the junction of the sleeve and the block, which affected the reliability of motors. The withdrawal of the sleeve on the level of the connector significantly increased the tightness of the sealing head of the cylinder head, this made it possible to use liquefied gas as fuel. Among the essential steps of modernization, I would note the use of piston rings of the Czech company Buzuluk and applying the sealant of the company "Hehkel". To reduce oil consumption, improve the working conditions of the piston rings and thereby increase the resource of the cylinder-piston group, instead of the traditional Honing Diamond Bru in the factory, the so-called soft surface treatment of the sleeve is used, in which significantly less pressure is provided for honing bars. To adapt the operation of the motor on gas fuel, changes and geometry of the pistons are made, the gaps in the interface of the sleeve valve are reduced, and the piston fingers are manufactured by cold extrusion. The connecting rod and the root cable of the crankshaft are hardened on the German automatic line "Aeg- Elotherm". To reduce the likelihood of gas rylot in castings of cylinder blocks, the degassing of aluminum alloys of the German company "Foseko" is mounted and launched.

Steir-Alpina Legend

The very first owners of the Nizhny Novgorod half-timer dreamed of economical and reliable diesel for her. And it is still not, although the production of SteeR licensed diesel engines in Nizhny since 1995, immediately renoving it to GAZ-560. But to this day it is a rare motor, unfamiliar carriers. However, there is a place in Russia where everything knows about him. Two years ago, about 800 "Gazelle" worked in St. Petersburg "Third Park" with these diesel engines. Agree, excellent statistical sample, you can make a reliable list typical breakdowns, despite the fact that the local engineers and repairmen have, with what to compare. On some routes with these "gazelles" there are cars with gasoline engines, and even with IVECO diesel engines and, in addition, Diesel Ford Transit and Mercedes Vario.

Diesel GAZ-560: experience, the son of difficult mistakes

The main feature of the engine Steyr M1 is a cylinder block combined with a head into a monoblock. Block and head - one casting, without fasteners or bolts, without any connector and therefore without gBC pads. From the bottom to the monoblock ten bolts M12 (it would seem, a diesel bolts must be thicker) the housing of the native crankshaft bearings (full-rod shaft) is fixed, and the same bolts attract the indigenous covers. On top of the monoblock, the camshaft housing is installed, the timing of the timber belt. So absolutely without the motor connectors does not work.

The monoblock design, in comparison with the engines with a removable head, there are two advantages. The first is higher rigidity at the same material intensity. Stiffness is needed to maintain the correct geometry at the cylinder sleeves. Consequently, the motor is obtained easier, although at a volume of 2-2.5 liters the difference will be small, about 10-15 kilograms. The second advantage is the lack of laying the head of the block, which from time to time goes on diesel engines. Whether the water goes to the cylinders, whether the oil falls into antifreeze, but the result is one - it is necessary to change the gasket. However, usually with this work for 4-6 hours, it can be a little longer, a more or less qualified driver or a 3th discharge motorist is successfully coping. The disadvantages turned out to be much more. The combination of a cunning Austrian design with russian features Operation - created a rare rattling mixture.

Monoblock was known at the beginning of the twentieth century, (remember AMO F-15, from which ZIL began), but the engines were then large and small, there was no need to make developed shirt channels made by reliable gears, and not a toothed belt, like Steyr M1. Often precisely with the replacement of the belt, the Austrian motor starts the problems. Belts going to the factory equipment are quite durable, and the frequency of their replacement, according to the gas instructions, is 120 thousand kilometers. But in the Third Park, the belts change preventively by 90 thousand. And all the same with the torn belts, two or three cars per day are dampped on the rope. One of the reasons is to replace there are no belts of the desired quality and reliability. On Steyr put imported belts of two firms, and both ripped in half the framework, and does not cut the teeth at all, as expected. One of these belts is thicker, it goes better, but it is hardly stretched on the gear pulley camshaft, and its back side - on the pulley of the water pump. It happens, pulls out the thread from the aluminum camshaft body, on which the stud is screwed tensioner roller Timing belt, then the belt is slipping into several teeth. There is only a thread M10, for recovery cut M12, it keeps more reliable.

OPINION

Igor Sibirevchief Engineer of OJSC "Third Park", St. Petersburg - during operation at the Gazelle license, the licensed diesel engine Steyr M1 money saved on fuel, hardly enough for its expensive repairs.

Foreign cars do not break?

It is known that there are some protection on the diesel engines of various manufacturers, reducing the engine damage when the belt is broken. Volkswagen, with a "meeting" of valves and piston, camshaft burst into several pieces, but it is still cheaper than changing the head. Cast iron 2.5 liter engines Ford Transit, produced by almost 20 years, up to the beginning of the third millennium, only the rods were bent. It was a very successful solution - leveled them with a hammer, put it in place, adjusted the valves, and you can ride further. Steyr during the belt break, at best, in half the same-sleeved valve levers are bursting - rockers. Everyone costs about 700 rubles, and their eight, and they will only have to spend 5,600 rubles on them. It happens that not all rockers break, but if they scatter on the fourth cylinder, you have to remove the camshaft housing, on the other three cylinders for replacement you can do without it. Accordingly, different labor intensity is obtained. If without removing the camshaft, then the experienced repairman can eliminate the breakdown in 1.5-2 hours, otherwise it will be twice as much. It seems not a very terrible defect, but the crumbs from the broken rockers fall into the pallet, and from there through a large grid of the oil processor - in the oil pump. What moves there can get to the liners of the crankshaft, to hope them. What is the resource there after that. It happens even worse when the belt break occurs on the crankshaft turns above average. Then the valves are bent, and to get to them, you have to remove the engine and fully disassemble it by violating the acquisition of many details. Such a breakdown can put a fear for several days or a couple of weeks a car with mileage of just 100 thousand kilometers. And it's not just the difficulty of repair, one of the reasons for the delay is a shortage of spare parts. As in the old times of the universal deficit, they are highlighted by the quota on Steyr, and if it is chosen, you will have to look for other suppliers, and the price can grow one and a half or twice.

In general, the main problems delivers the monoblock. On average, it runs 200-300 thousand kilometers on the minibus to the steyr, if lucky - a little more. For comparison, diesel engines have a heavier Ford Transit go minimum two times better, in the same "third park" there is a car that has worked without capitals more than a million. Perhaps, on the "Volga" with one owner, Steyr will serve longer, but on Gazelle - this is exactly the case.

Designed engine ZMZ. 406 to replace 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.

DVS ZMZ 406.

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.

Carburetor version ZMZ 4061.10

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.

Valve hydro pulls

After the changes made specifications ZMZ 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.

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 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. Power compression of DVS Increased plant designers to 9.3 in the basic version 4062.10 due to the central location of the candle inside the combustion chamber.

Design of gas distribution mechanism

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.

Tensioner chain timber

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.

Version of the motor ZMZ 406 is characterized by combustion chambers

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.

Inlet intake manifold

List of car models in which installed

Since the Motor ZMZ 406 has three versions, each of them was used on specific models Auto manufacturer Gas:

• 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.

GAZ Gazelle farmer

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.

Repair ZMZ 406.

The manufacturer recommends using for engines high-quality lubricantSo that hydrocompensators and oil pump work properly. Initially, the cooling system has weaknesses - radiator and thermostat. Everything hinged equipment 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).

Tuning ZMZ 406.

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.