Created on the basis of the Saab 900 sports engine, the 406 Gazelle injection engine has been installed since 1996 on cars of the Volga, Gazelle, and UAZ brands. Here instead of the usual carburetor system power supply installed injection, which significantly improved performance characteristics - power, efficiency, etc. This unit operates under the control of electronics, its design differs from the carburetor one.

Benefits

Reliability, efficiency, power of the injection unit are significantly superior to its carburetor counterpart. Therefore, the 406 Gazelle engine is installed on such car brands where higher performance is required:

• Reliability, uninterrupted operation are ensured due to the design features - there are no jets, so nothing gets clogged in the power system.
• Economical - the whole process is electronically controlled.
• Due to the timely supply of fuel of the required amount, the injection engine can develop power up to 130 liters. from. (carburetor - up to 100 liters. from.).
• There are no idles.
• Significantly lower emissions of harmful substances.

The only negative is because of electronic system adjustment, in case of a breakdown during the journey, you will not be able to make repairs yourself. But with careful operation, refueling quality fuel, the timely passage of TO the injection engine will not cause big problems.

Design

The model 406 injection engine is represented by an in-line 4-cylinder engine, the number of valves is 16. The fuel injection is controlled electronically. Runs on gasoline.

Design features:

• 4 valves in each cylinder;
• the camshafts are located at the top of the cylinder block;
• the compression ratio is increased due to spark plugs, injection system (is 9.3);
• cast iron cylinder blocks, more durable, in contrast to aluminum, which is equipped with a carburetor unit;
• improved oil filter with additional elements;
• improved ignition system;
• parts are made of modern technological materials, their weight parameters are reduced;
• the piston stroke is reduced (is 86 mm);
• installation of a chain of an original design, which performs the function of a camshaft drive, which is equipped with hydraulic tensioners that work automatically.

Installation of LPG

The operation of the engine on gas fuel is much more economical (cheaper than gasoline), gas does not remove the protective oil film from the cylinders, and the risk of detonation is reduced. But for a 406 injection engine, its installation is impractical. For HBO, a gas dosing system is required, but they are all produced of a carburetor type. Therefore, the unit will operate like a carburetor unit - without precise dosage of fuel in different operating modes.

Possible breakdowns and repair options

The 406 injection motor is completely repairable and you can fix some problems yourself:

• The engine does not start immediately - in most cases due to a broken temperature sensor. It is necessary to check its serviceability, replace if necessary.
• Does not start - the timing chain may have jumped off or gone off the marks. It is necessary to check it, correct it, setting it by the marks.

Good enough modern engine with good technical characteristics. Produced by the Zavolzhsky Motor Plant. Unlike the previous model of ZMZ engines, namely the 402 has 16 valves per 4 cylinders, a compression ratio of 9.3 and some other details.

or carburetor have some difference in the index. The injector has the designation ZMZ 4062, and the carburetor ZMZ 4061 and ZMZ4063.

However, the biggest difference lies elsewhere. 406 engine injector has better specifications compared to their carburetor counterparts. With the same weight (about 190 kg) and the same volume of 2.3 liters, the engine power is 150 hp, which is much more than the power of engines with a carburetor. (100 and 110 hp respectively). The maximum torque is also higher than 206 N * m, against 181 and 191 N * m in 4061 and 4062. Such higher characteristics allow you to carry more cargo and easier to cope with bad roads.

It may seem that fuel consumption is more powerful engine, that is, the injection 406 should have more. But no. Fuel consumption is significantly lower per horsepower. 185 grams. But the 406 carburetor consumes 195-200 grams.

Although the 406 injection engine is better, it has a rather complex power supply and control system that requires professional attention. However, with proper care, this engine has proven itself to be reliable, powerful and fast, and usually does not cause trouble for maintenance personnel.

This power unit is installed on domestic cars middle class. This engine was installed on a large number of cars of the GAZ brand and, in particular, for various versions of the Gazelle and Volga vehicles.

ZMZ-406 family represents gasoline car engines internal combustion, manufactured by JSC "Zavolzhsky Motor Plant".
Prototypes have been assembled since 1992, in series production since 1997.
Fuel injection was used for the first time.
This family of engines was widely used on cars of the Gorky Automobile Plant, such as: Volga-3102, 31029, 3110 and GAZelle.
The flagship of the family - ZMZ-4062.10 - is a 2.28-liter 16-valve engine capable of developing power up to 150 hp.

The ZMZ-4062.10 engine is designed for installation on cars middle class and minibuses.

Engines ZMZ-4061.10, ZMZ-4063.10 are intended for installation on trucks small payload type "Gazelle" and minibuses.

Specifications

Engines ZMZ-4061, ZMZ-4063

- carburetor, four-cylinder, in-line with microprocessor ignition control system.

The general view of the motors is shown in Figures 1 and 3.

The cross section of the motors is shown in Figure 2.

Picture 1.
Engines model ZMZ-4061 and ZMZ-4063 (left side view)

1. drain plug;
2. oil sump;
3. exhaust manifold;
4. engine support bracket;
5. coolant drain valve;
6. water pump;
7. emergency coolant temperature sensor;
8. coolant temperature gauge sensor;
9. temperature sensor of the engine;
10. thermostat housing;
11. emergency oil pressure sensor;
12. oil pressure indicator sensor;
13. oil level indicator (dipstick);
14. ignition coil

Figure 2.

• 1 - oil sump;
• 2 - oil pump receiver;
• 3 - oil pump;
• 4 - oil pump drive;
• 5 - gear wheel of the intermediate shaft;
• 6 - cylinder block;
• 7 - inlet pipe;
• 8 - ventilation pipes;
• 9 — camshaft intake valves;
• 10 - inlet valve;
• 11 - valve cover;
• 12 - exhaust camshaft;
• 13 - oil level indicator (dipstick);
• 14 - valve hydraulic pusher;
• 15 - external valve spring;
• 16 - valve guide sleeve;
• 17 - exhaust valve;
• 18 - cylinder head;
• 19 - exhaust manifold;
• 20 - piston;
• 21 - piston pin;
• 22 - connecting rod;
• 23 - crankshaft;
• 24 - connecting rod cover;
• 25 - main bearing cover;
• 26 - drain plug;
• 27 - pusher body;
• 28 - guide sleeve;
• 29 - compensator body;
• 30 - retaining ring;
• 31 - compensator piston;
• 32 - ball valve;
• 33 - ball valve spring;
• 34 - ball valve body;
• 35 - expanding spring

Figure 3.

1. synchronization disk;
2. synchronization sensor;
3. oil filter;
4. starter;
5. knock sensor;
6. a pipe for draining the coolant from the heater;
7. inlet pipe;
8. hydraulic chain tensioner;
9. generator;
10. generator belt;
11. water pump pulley;
12. tension roller;
13. gasoline pump

The main design features engines are the upper (in the cylinder head) arrangement of two camshafts with the installation of four valves per cylinder (two intake and two exhaust), increasing the compression ratio to 9.3 due to the combustion chamber with a central position of the spark plug.

These technical solutions have increased the maximum power and maximum torque, reduced fuel consumption and reduced exhaust emissions.

To improve reliability, a cast-iron cylinder block without plug-in liners was used on the engine, which has high rigidity and more stable clearances in friction pairs, the piston stroke was reduced to 86 mm, the mass of the piston and piston pin was reduced, and better materials were used for crankshaft, connecting rods, connecting rod bolts, piston pins, etc.

Camshaft drive - chain, two-stage, with automatic hydraulic chain tensioners; the use of hydraulic pushers of the valve mechanism eliminates the need to adjust the clearances.

Application hydraulic devices and forcing the engine require high Quality oil purification, therefore the engine uses a full-flow oil filter of increased efficiency ("superfilter") of single use. An additional filter element of the filter prevents the ingress of crude oil into the engine when starting a cold engine and clogging of the main filter element.

The microprocessor-based ignition control system allows you to adjust the ignition timing, including by the detonation parameter under varying engine operating modes, which allows you to provide the necessary indicators - power, economic and exhaust gas toxicity.

Drive unit auxiliary units (coolant pump and generator) is carried out by a flat poly V-belt.

The engine is equipped with a diaphragm clutch with ellipse-wound clutch plates of the driven disc, which have high durability.

The GAZ car brand is known all over the world. In recent decades, the quality power plant the 406 engine produced by the Zavolzhsky Motor Plant is installed on the main products of this automobile giant. The construction of this power unit worked out for several years. The foundation was laid at the end of the last century, it was then that the basic concept of the ZMZ 406 was formulated. Today it is a promising power-packed unit capable of developing a capacity of up to 150 liters. from. (110 kW).

Technical characteristics of the ZMZ-406 engine

The four-cylinder in-line engine is made according to the classic scheme typical for the power plants of the Zavolzhsky Motor Plant, this is how you can start the characteristic of the 406 engine. The working volume is 2.28 liters.

The combustion chamber features a centrally positioned spark plug. The timing belt ZMZ 406 is made quite original, which made it possible to compactly arrange the main elements of the power system.

The crankshaft speed at maximum power is 5200 rpm, and the maximum torque is observed at significantly lower rpm, which is 4000 rpm. in min. The engine maintains the minimum speed in the region of 750-800 rpm 406 at idle speed.

Design features of the 406 engine produced by ZMZ

As a prototype for the project, a motor from sports car "Saab-900". The first gasoline engines ZMZ-406 appeared in the early eighties of the last century.

The ZMZ-406 has some features:

1. The block is cast from cast iron. It is, of course, heavier than aluminum, but the use of this metal eliminates the need for replaceable liners (cylinders). In this regard, the rigidity of the structure has increased.
2. In the upper part, there are two ZMZ 406 timing belts (gas camshafts of the intake-exhaust system). Each of the shafts is responsible either for the intake of a fresh charge of the working mixture, or for the release of exhaust gases.
3. There are four valves in the head for each cylinder. That is, sixteen valves are installed on the entire four-cylinder. This amount increases the efficiency of cylinder purging when exhausting exhaust gases and increases the ratio of filling the cylinders with fresh working mixture.
4. A special innovation was used for the first time on this particular power unit - the hydraulic chain tensioner. It made it possible to maintain the optimal tension in the ZMZ 406 timing drive. This technical solution was later repeated in dozens of other designs. But the timing belt ZMZ 406 was the firstborn in the domestic engine building, where it was applied.
5. For this engine options were thought out to reduce the piston stroke, which is only 86 mm, while the cylinder diameter is 92 mm. This approach increased the compression ratio to 9.3. This is a very high value. But in theory it is argued that with an increase in the compression ratio, the efficiency of the power plant also increases. The short stroke of the piston contributes to better filling.
6. ZMZ 406 was solved according to the traditional scheme. The coolant is moved by the ZMZ 406 pump through the block, the block head and the radiator.
7. There is also a feature - a flat poly V-belt is used, which excludes the possibility of an unexpected break.
8. The ZMZ 406 thermostat allows you to organize circulation in a small circle during the engine warm-up period, and when the warm-up temperature is reached, the thermostat opens, letting the coolant in a large circle.
9. The crankshaft pulley ZMZ 406 transmits torque to the shaft of the ZMZ 406 pump, which supplies coolant to the car's stove, maintaining an optimal microclimate in the cab in the cold season.
10. The coolant temperature sensor helps the driver to constantly monitor the temperature.
11. The 406 also has a lubrication system. Gear pump engine oil moves from the oil pan, is supplied under pressure for cleaning, where in oil filter ZMZ 406 removes impurities larger than 40 microns. The purified oil is forcibly fed into the channels of the ZMZ 406 crankshaft, moving inside the main and connecting rod journals, providing stable lubrication in these nodes, experiencing huge alternating loads. Some of the oil moves further under pressure, lubricating the piston pin. Then the oil gets on the surface of the piston. The piston interacts with the cylinder mirror of the ZMZ 406 engine by means of an oil film formed in the contact zone.

The difference between the injection and carburetor fuel systems

During the first decade of the ZMZ 406 production, the carburetor engine was responsible for preparing the working mixture. Now, an injection modification of this motor is being produced.

The use of an injector made starting easier, improved throttle response and reduced fuel consumption. What is the reason here?

It is known from the internal combustion engine theory that the increase in carburetor performance depends on the crankshaft speed. The consumption of the combustible mixture increases as this indicator rises. Sharp pressing on the accelerator pedal leads to the fact that the relative content of gasoline vapors in the ZMZ 406 carburetor increases. The excess air ratio decreases slightly, which leads to an increase in torque and an increase in the crankshaft speed.

The ZMZ 406 engine injector works a little differently. Here the microprocessor helps, which clearly reacts to the position of the control pedal. If necessary, increase the speed and light pressing more fuel is injected into the cylinder on the pedal. The time interval between the load and its correction in any injection engine is reduced several times. This increases throttle response, improves the dynamics of the Gazelle or Volga (depending on which car the ZMZ 406 injector is installed on).

The main reason for the high performance of the injection system compared to the carburetor system is the absence of jets, which regularly clog.

This led to the need for periodic blowing, and often mechanical cleaning of small-diameter holes. Of course, if on the road injection system refuses, then not every driver will be able to fix it on their own.

Engine tuning

Tuning ZMZ 406 is a way to change the output. Many drivers are looking for ways to improve the performance of their vehicles.

Someone is not satisfied with the available power, others are embarrassed by the gluttony of the motor, others simply want to excel by choosing one or another option that they want to optimize.

The first thing powerplant specialists do is increase power:

1. You can simply bore the cylinder and use larger pistons. But this path is fraught with a decrease in the strength of the block.
2. More often they go the other way - they force it by increasing the air supply due to mechanically driven turbines or using turbocharging.

The first way is easier, but it should be taken into account that it is required to create a mechanism with a high gear ratio - the turbine speed is at the level of 10-15 thousand rpm. Such a drive, forcing the engine, creating tuning for the ZMZ 406, is difficult to perform. More often they follow the path of using a turbocharger.

The turbocharger uses the energy of the exhaust gas to operate. ZMZ 406 turbo, a gas inlet to the turbocharging system is installed on the exhaust part. On the same shaft with the turbine there is also a compressor that pumps a clean charge of air into the cylinders of the ZMZ 406 engine. The filling is growing. The cyclic fuel supply increases proportionally, which leads to an increase in the amount of the working mixture in the cylinder, and, accordingly, the gas pressure also increases, which leads to an increase in torque. Further, the power also grows.

In the theory of internal combustion engines, it is stated that an increase in power during turbocharging is accompanied by a decrease in specific fuel consumption. ZMZ 406 tuning in this way allows you to improve not only the dynamics of the car, but also to improve its efficiency.

In the eighties of the last century, another direction of boosting was worked out - this is dynamic boost, the essence of which was to select the parameters of the intake system so that the frequency of pulsations of the air flow at the intake corresponded to the resonant frequency of the system itself.

Mathematical models have been proposed to calculate the optimal diameters and lengths of the intake system. A number of specialists also installed mechanical resonators, which, through special membranes, transmitted pulses from the exhaust system to the intake system. This way allows not to change the engine 406 drastically, but at the same time to achieve an increase in power and a decrease in specific fuel consumption.

The ZMZ 406 engine can be modified and easier. It is enough to grind the inlet and outlet ports in the fuel system. This optimization, when combined with the GAZelle 406 engine, allows for improved dynamics. The combination of the ZMZ 406 on the UAZ with polished channels will pleasantly surprise the user, the car will pleasantly resemble an energy-rich passenger car.

Popular mistakes of motorists

The pursuit of an increase in power for some motorists is reduced only to alteration of the ZMZ 406 engine. But not all alterations are good. And some are harmful, this is the reverse tuning or anti-tuning:

1. There are rumors on the internet that you can increase engine power by reducing the weight of the flywheel. At the same time, the authors emphasize that the flywheel takes power and increases the weight of the engine. In fact, the flywheel stores the energy that this engine receives in the "working stroke" cycle for performing the remaining cycles in four-stroke engine... With an increase in the number of cylinders, the relative mass of the flywheel decreases, but this is due to a change in the number of strokes per crankshaft revolution, since more pistons are involved in the work. Ideally, if the number of working cylinders is brought to infinity, then a flywheel is not needed at all.
2. There are experts who recommend installing air swirlers in the intake system. But such specialists do not understand that when the air flow moves, a turbulent flow regime is observed. Turbulence, by definition, is motion with a vortex flow, as Bernoulli proved over 150 years ago. Excessive interference will only reduce the amount of air charge and reduce power, which will affect the engine's economy.
3. Recently, ideas have appeared to warm up the air at the intake - they say that the 406 engine will add power to the injector. But this is not true. The charge density of the air decreases with heating and constant pressure. Consequently, its total number also decreases. And this leads to the fact that the pressure drops during the combustion of the mixture, the power drops instead of growth.
4. There are also authors who have been repeating for more than forty years that the injector should be supplied with water droplets into the intake tract of the ZMZ 406. But remember that designers are looking for ways to separate fuel and water to make the combustion process more intense. Water entering the cylinder at a high temperature will begin to cause intense corrosion. When fuel is burned, the exhaust gas contains carbon monoxide and water vapor. Those who have been using motors for a long time know that zMZ engine 406 does not need to be used in ways that impair its reliability.
5. There was also a group of "experts" who recommend to optimize the engine by replacing the hydraulic chain tensioner. They advocate the installation of an electric tensioner, while the scheme of a vicious device should be redeemed from them for a lot of money. It's already absurd to pay to ruin the power plant.

Therefore, listening to the advice of different specialists, it should be remembered that designers do not understand their business much better than ordinary people. It is not in vain that they abandon many ideas that will ruin the engine.

On which cars is the ZMZ-406 engine used

The modern engine of the Zavolzhsky Motor Plant of the 406th model is installed on GAZ-3110 "Volga" cars and 3302 trucks.

The motor and automobile plants of the Nizhny Novgorod region constantly monitor their products, collect information on the operation of the manufactured equipment.

Of course, sometimes certain conflict situations arise.

They are connected with the fact that drivers contact with questions:

• troit the Gazelle engine;
• timing marks are not visible;
• injectors fail;
• the pump fails;
• ZMZ piston;
• the oil filter is leaking;
• the thermostat is unstable;
• basic technical characteristics and others are not met.

Manufacturers are always trying to provide assistance through their service centers, which are scattered throughout Russia and the CIS.

GAZ-24 - soviet car middle class, produced by Gorkovsky Automobile Factory from 1968 to 1986, this car was in the USSR, perhaps the most ...
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ZMZ-406 engine

ZMZ-406 engine

In recent decades, the -406 engine produced by the Zavolzhsky Motor Plant has been installed as a power plant for the main products of the automobile giant GAZ. The design of this power unit has been perfected over several years. The foundation was laid at the end of the last century, it was then that the basic concept of ZMZ 406 was formulated. Today, it is a promising power-packed unit capable of developing a capacity of up to 150 liters. from. (110 kW).

During the first decade of the ZMZ 406 production, the carburetor engine was responsible for preparing the working mixture. Now, an injection modification of this motor is being produced.
The use of an injector facilitated starting, improved throttle response and reduced fuel consumption. What is the reason here?
It is known from the internal combustion engine theory that the increase in carburetor performance depends on the crankshaft speed. The consumption of the combustible mixture increases as this indicator grows. A sharp press on the accelerator pedal leads to the fact that the relative content of gasoline vapors in the ZMZ 406 carburetor increases. The excess air ratio is slightly reduced, which leads to an increase in torque and an increase in the crankshaft speed.

The ZMZ 406 engine injector works a little differently. Here the microprocessor helps, which clearly reacts to the position of the control pedal. If it is necessary to increase the speed and lightly press the pedal, more fuel is injected into the cylinder. The time interval between the load and its correction in any injection engine is reduced several times. This increases throttle response, improves the dynamics of the Gazelle or the Volga (depending on which car the ZMZ 406 injector is installed on).

Engine ZMZ-406 specifications

Manufacturer	ZMZ
Years of release	1997-2008
Brand	406
A type	petrol
Supply system	injector / carburetor
Control block	MIKAS
Configuration	4-cylinder in-line longitudinal internal combustion engine
Ignition	commutator
Maximum power	100 h.p. 73.55 kW (90 HP) at 4500 rpm
Working volume	2,286 cm 3 (2.3 L)
Maximum torque	177/201 Nm at 4200 rpm
Cylinder diameter	92 mm.
Piston stroke	86 mm
Compression ratio	9,3
Cylinders	4
The order of the cylinders	1-3-4-2
Location of the first cylinder	TBE
Valves	16
Cylinder head material	aluminium alloy
Intake manifold	duralumin
Exhaust manifold	cast iron
Camshaft	2 pcs. DOCH
Crankshaft	lightweight
Oil consumption	max 0.3 l. for 1000 km.
Oil type by viscosity	5W30, 5W40, 10W30, 10W40
Recommended manufacturer	Liqui Moly, Lukoil, Rosneft
Recommended by season	in winter-synthetic, in summer-semi-synthetic
Engine oil volume	6.1 l.
Operating oil temperature	90 o
Oil consumption per 1000 km.	up to 100 g
Ecology standards	Euro 3 / Euro 0
Engine parts ZMZ-406
Adjustment of valves	gyro pushers
Cooling system	forced, antifreeze
water pump	with plastic impeller
Spark plug	A14DVRM or A14DVR
Candle gap	1.1 mm.
Valve train chain	70/90 with shoe il 72/92 with sprockets
Noise filter	Nitto, Knecht, Fram, WIX, Hengst
Oil filter	with non-return valve
Flywheel	7 holes offset 40 mm. inner diameter
Flywheel Bolts	М12х1.25, length 26 mm.
Goetze valve stem seals	light-inlet, dark-outlet
Idling speed	750-800 min -1
Tightening forces of threaded connections
Candles	31-38 Nm
Flywheel	72-80 Nm
Clutch bolt	19-30 Nm
Bearing cover	98-108 Nm root
Bearing cover	67-74 Nm connecting rod
Cylinder head	three stages 40 Nm, 127 - 142 Nm + 90 o
Coolant volume	10 l.
Cooling system	forced, antifreeze
Internal combustion engine resource	150000-200000 km.
Unit weight	192 kg.