The ZMZ 406 engine was developed to replace the 402 engine simultaneously with the design of the GAZ-3105 car for the government. However, these new Volgas were completed with them only in the last batch, which had to be urgently sold in connection with the removal of cars from production.

ICE ZMZ 406

The ZMZ 402 (equipment) and the H-series engine of the SAAB manufacturer (design solutions) were taken as the basis. As a result, with the same volume of 2.3 liters, the power drive provided 177 Nm of torque instead of 210 Nm of the prototype and 100 hp. With. power instead of the expected 150 hp, like the Swedish internal combustion engine. injection system, which was later replaced by a carburetor, was able to correct the situation a little - 201 Nm and 145 hp. s., respectively.

Carburetor version ZMZ 4061.10

For the first time, several advanced technical solutions for that time were used in the engine of the manufacturer ZMZ:

• two intake and two exhaust valves per cylinder;
• electronic ignition and injection systems;
• diagram of the DOCH gas distribution mechanism with two overhead camshafts;
• hydraulic pushers instead of adjustment thermal gap valve gaskets.

Valve lifters

After the changes specifications ZMZ 406 correspond to the values ​​​​given in the table:

Manufacturer	ZMZ
ICE brand	406
Production years	1997 – 2008
Volume	2286 cm 3 (2.3 l)
Power	73.55 kW (100 HP)
Torque	177/201 Nm (at 4200 rpm)
Weight	192 kg
Compression ratio	9,3
Nutrition	injector/carburetor
motor type	in-line petrol
Ignition	switching
Number of cylinders	4
Location of the first cylinder	TVE
Number of valves per cylinder	4
Cylinder head material	aluminum alloy
Intake manifold	duralumin
Exhaust manifold	cast iron
camshaft	2 pcs. DOCH scheme
Block material	cast iron
Cylinder diameter	92 mm
Pistons	original
Crankshaft	lightweight
piston stroke	86 mm
Fuel	AI-92/A-76
Environmental standards	Euro-3/Euro-0
Fuel consumption	highway - 8.3 l / 100 km combined cycle 11.5 l/100 km city ​​- 13.5 l / 100 km
Oil consumption	maximum 0.3 l/1000 km
What kind of oil to pour into the engine by viscosity	5W30, 5W40, 10W30, 10W40
Which oil is best for the engine by manufacturer	Liqui Moly, LukOil, Rosneft
Oil for ZMZ 406 by composition	Synthetic in winter, semi-synthetic in summer
Engine oil volume	6.1 l
Operating temperature	90 °
ICE resource	claimed 150,000 km real 200,000 km
Adjustment of valves	hydraulic pushers
Cooling system	forced, antifreeze
coolant volume	10 l
water pump	with plastic impeller
Candles for ZMZ 406	domestic A14DVRM or A14DVR
spark plug gap	1.1mm
Valve train chain	70/90 with shoe or 72/92 with sprockets
The order of operation of the cylinders	1-3-4-2
Air filter	Nitto, Knecht, Fram, WIX, Hengst
Oil filter	with check valve
Flywheel	7 offset holes, 40 mm inner diameter
Flywheel mounting bolts	M12x1.25 mm, length 26 mm
Valve stem seals	Goetze, bright inlets dark graduation
Compression	from 13 bar, difference in neighboring cylinders max. 1 bar
Turnover XX	750 - 800 min -1
Tightening torque for threaded connections	candle - 31 - 38 Nm flywheel - 72 - 80 Nm clutch bolt - 19 - 30 Nm bearing cap - 98 - 108 Nm (main) and 67 - 74 (connecting rod) cylinder head - three stages 40 Nm, 127 - 142 Nm + 90 °

The factory manual contains a more precise description of the parameters:

• ZMZ 4063.10 - carburetor, compression ratio 8 for operation on A-76 fuel, power 110 hp. s., torque 186 Nm, weight 185 kg;
• ZMZ 4061.10 - carburetor, compression ratio 8 for A-76 gasoline, power 100 hp. s., torque 177 Nm, weight 185 kg;
• ZMZ 4062.10 - injector, compression ratio 9.3 for AI-92 fuel, power 145 hp. s., torque 201 Nm, weight 187 kg.

ZMZ 4063.10
ZMZ 4062.10 injector

Officially, the ZMZ 406 engine became the third after 24D and 402 in the line of power drives of the Zavolzhsky plant. Got microprocessor ignition, DOCH timing scheme with two-stage chain drive.

The developers still used an in-line engine layout with 4 cylinders, but there were two camshafts, they are located on top, inside the cylinder head. The compression ratio of the internal combustion engine was increased by the plant designers to 9.3 in the basic version 4062.10 due to the central location of the candle inside the combustion chamber.

The design of the gas distribution mechanism

Reliability is enhanced by a cast-iron cylinder block without liners, a reduction in piston stroke to 86 mm and the weight of the entire group of SHPGs. Connecting rods with bolts, crankshaft and piston rings Made from high quality materials, so overhaul less often required.

Timing chain tensioner

Automatic chain tensioners double action– spring preload during hydraulic operation. The degree of oil purification is increased by installing a full-flow disposable filter. A separate V-belt drive is provided for attachments. ECU firmware corresponds to SOATE, ITELMA VS5.6, MIKAS 5.4 or 7.1 versions

List of engine modifications

Initially, the motor was designed with injection, so version 4062.10 is considered the base one. The need for carburetor modifications 4061.10 and 4063.10 arose later. They were installed on the Gazelle, therefore, while maintaining the volume of the combustion chambers, it was necessary to reduce the operating costs of the owner. To do this, the management of ZMZ lowered the compression ratio in order to transfer the engines to cheaper A-76 fuel.

Versions of the ZMZ 406 engine differ in combustion chambers

With motors 4061 and 4063, a reverse modernization was made:

• reduced power and torque;
• revolutions XX steel 750 min -1 instead of 800 min -1 ;
• maximum torque is reached at 3500 rpm, not at 4000.

Everything else mounted is located in the same places without changes. Some of the parts are interchangeable, with the exception of the cylinder head and piston.

Pros and cons

A negative feature of the ZMZ 406 power drive is the low quality of casting and unsuccessful technical solutions:

• high oil consumption due to the unfinished design of the rings;
• low timing resource of the drive due to the tensioner, collapsible block star and bulky design in general.

Fuel consumption is high, but this is typical for most truck engines.

But vibrations are reduced, the cylinder head does not unscrew during operation, the gasket does not need to be constantly changed, and the nuts need to be tightened. The maintainability of all nodes is high, the design itself is reliable and simple. The user is relieved of the need to adjust the valve clearances every 20,000 runs.

intake manifold injector

List of car models in which it was installed

Since the ZMZ 406 engine has three versions, each of them was used on specific models of the GAZ car manufacturer:

• ZMZ 4062.10 - GAZ 31054 of the Lux configuration; GAZ 3102 (1996 - 2008);
• ZMZ 4061.10 - GAZ 3302, 33023, 2705, 3221;
• ZMZ 4063.10 - GAZ 3302, 33023, 2705, 3221, 32213, 322132, 32214, SemAR 3234, Ruta, Bogdan and Dolphin.

GAZ Gazelle Farmer

In the first case, the engine characteristics were suitable for the urban executive cars of officials and the government. Carburetor modifications reduced the operating budget of Gazelle vans, utility cars and trucks.

Maintenance schedule ZMZ 406 2.3 l / 100 l. With.

According to the manufacturer's requirements, the ZMZ 406 engine is serviced in the following order:

• inspection of the timing chain after 30,000 runs, replacement after 100,000 km;
• oil and filter change after 10,000 km;
• coolant replacement approximately every two years or 30,000 mileage;
• recharging the battery every autumn, replacing after 50,000 km;
• spark plugs last for 60,000 runs;
• the fuel filter becomes unusable after 30,000 km, the air filter - 20,000 km;
• ignition coils fail after 50,000 runs.

Repair ZMZ 406

The manufacturer recommends using for engines quality lubricant so that the hydraulic lifters and oil pump work properly. Initially, the cooling system has weak spots- Radiator and thermostat. Everything attachments high resource, with the exception of the pump, the polymer rotor of which lasts about 30,000 km. Due to the heavy weight of the motor with your own hands, it is very difficult to overhaul in a garage without a hoist.

Overview of faults and how to fix them

By virtue of design features the ZMZ 406 motor bends the valve only when the chain jumps. Moreover, they are damaged against each other (inlet and outlet while lifting), and not about the pistons. If the circuit breaks, this trouble will not happen.

Since the ICE device is partially copied from SAAB, and the ZMZ 402 design is partially preserved, it is characterized by malfunctions:

High RPM XX	1) sensor failure 2) there is no contact of the regulator XX 3) torn crankcase ventilation hoses	1) replacement of sensors 2) contact recovery 3) replacement of hoses
Cylinder failure	1) ECU malfunction 2) failure of the coil 3) breakdown of the tip of the candle 4) nozzle failure	1) replacement of the control unit 2)coil repair 3) tip replacement 4) repair / replacement of the nozzle
Unstable operation of the internal combustion engine	1) air suction 2) water in the fuel tank	1) restoration of tightness, replacement of gaskets 2) draining gasoline, drying the tank
Motor does not start	1) failure of the ignition system 2) fuel supply is broken	1) replacement of the coil, contact 2) replacement of the filter, pressure reducing valve, phase adjustment, replacement of the fuel pump

Due to the large diameter of the pistons, the block and cylinder head are sensitive to overheating, so the level of working fluids should be monitored regularly (oils and antifreeze).

Motor tuning options

Initially, the ZMZ 406 engine allows you to increase the power on your own up to 200 - 250 hp. With. For this, mechanical tuning is used:

• installation of a zero resistance filter;
• decrease in air temperature in the intake tract;
• replacement of the standard K-16D carburetor with Solex (adjustment with quality / quantity screws is necessary).

Tuning ZMZ 406

For Gazelle minibuses and trucks, turbo tuning is ineffective, since the operational life of the DS decreases and fuel consumption increases sharply.

Thus, the injector modification of ZMZ 4062.10 and carbureted versions 4061.10, 4063.10 are developed on the basis of the Swedish H-series engine for trucks and executive class auto. Tuning is allowed, primarily to increase torque.

Differing from them in greater power and better dynamics with a smaller working volume (2.3 liters versus 2.5 for 402), besides, the new engines turned out to be more economical. In the first years of production, carburetor engines were installed on GAZ vehicles, then they were gradually replaced by injection engines.

ZMZ 406 engine for GAZ vehicles

On cars "Volga" and "Gazelle" were used:

• 4061.10 - carburetor on 76 gasoline (compression ratio - 8);
• 4062.10 - injection on 92 gasoline (compression ratio - 9.3);
• 4063.10 - carburetor on 92 gasoline (compression ratio - 9.3).

On some GAZ vehicles, other engines of the Zavolzhsky Motor Plant were also used, for example, ZMZ-405.
Since 2006, only injection engines, more modern and with better performance, have been installed on Gazelle and Volga cars. The disadvantages inherent in carburetor options are a thing of the past.

ZMZ-406 - in-line four-cylinder engine. Its main part is the cylinder block made of gray cast iron.

Disassembled motor ZMZ 406

It is heavier than aluminum, but has increased rigidity and does not require replaceable sleeves.
The design of the engine has changed significantly compared to the previous model (ZMZ-402). An important feature is that there are two camshafts in the cylinder head, one of which is designed for intake valves, the other for exhaust valves. Their drive is chain, two-stage, with hydraulic tensioners operating in automatic mode.

Each cylinder has four valves to improve the intake of the working mixture and the exhaust gases. The valves are actuated by hydraulic pushers and do not require gap adjustment. Spark plugs are located in the center of the combustion chambers, which allowed to increase the compression ratio.

Main technical data ZMZ-4062.10:

Comparison of technical characteristics of various modifications of the ZMZ-406 engine

• Weight, kg - 192;
• Volume, liters - 2.28;
• Compression ratio - 9.3 (8 *);
• Power, l. With. - 145; one hundred*; 110**;
• Torque, Nm - 200.9; 181.5*; 191.3**;
• Brand of gasoline - AI-92, A-76 *;
• Volume of oil, liters - 6;
• Coolant volume, liters - 10.5.

Read also

Technical characteristics of the all-wheel drive Gazelle

* - data for 4061.10; ** - for 4063.10.
Due to the use of hydraulic mechanisms, 406 engines have increased requirements for oil quality. Provides good cleaning oil filter full flow with replaceable element. The design provides for a bypass valve through which oil is supplied in cases where it is difficult to pass through the main filter (it is dirty or thick oil after starting a cold engine). The valve has its own additional filter.

Comparison of injection and carburetor engines

The main difference between these modifications in the method of preparation and intake combustible mixture into the combustion chamber.

Carburetor for ZMZ 406 engine

On the carburetor 4061 and 4063, the traditional method was used, on the injector 4062, a new (for that time) version of gasoline injection through nozzles, controlled by an electronic microprocessor, was used.
When using injectors, the accuracy of fuel dosage increases, injection and ignition of it occurs at the optimal moment. Engine performance increases, power and torque increase, which is clearly seen when comparing the characteristics of injection and carburetor engines (see above).

ZMZ 406 injection engine ready for installation

Besides the best performance, injection engines are more economical and cause less damage to the environment. This is due to more complete combustion of fuel under control. electronic unit that does not require regular maintenance.

Have carburetor engines has its advantages. This is a simple design, the ability to adjust and repair without the involvement of specialists. True, this can turn into a disadvantage: if the carburetor is set incorrectly, various negative phenomena occur, for example, unstable turns on the Idling... If you are not confident in your abilities, it is better to contact the workshop.

Features of the injection engine power system

It is one of the main ones on the engine, it does not require adjustment, but you still need to monitor its condition. The injectors and pressure regulator work normally only on clean gasoline. Refuel at proven gas stations, sometimes (preferably in the fall) drain the sludge and water from the tank. If there are smudges on the fuel lines at the connectors, they must be sealed (tighten the fitting without excessive effort or replace the seals).

Cracked hoses should be replaced to avoid rupture. But keep in mind that the fuel in the lines behind the fuel pump is under high pressure (about three atmospheres), when the system elements are disconnected, it must be reset.

To do this, turn off the fuel pump (the easiest way is to remove the corresponding fuse), start the engine and wait: it will run out of fuel in the system and stall.

Start the starter (do not press the gas pedal) for a few seconds. Remove the negative battery terminal to prevent accidental sparks. Now you can detach the desired elements.
After completing the work, do not forget to replace the fuel pump fuse and terminal. Turn on the ignition and wait a few seconds, the pump will pump fuel into the system. Start the engine and check for leaks.

Read also

Adjusting the valves of the engine 4216 on the Gazelle

Determining a malfunction in the engine management system

This system receives information from various sensors installed on the engine, the normal operation of the power and ignition units depends on it. There is an opinion that it is possible to determine a malfunction in this system only in technical center using special devices. This is not entirely true, you can find the problem yourself.

A malfunction is signaled by the " check engine» on the instrument panel, lit continuously. Each malfunction has its own code, which the system writes to memory, the task is to obtain it and determine the cause using a special table.

To find out the code, find the diagnostic connector located in engine compartment on right. Remove the cover from it and close contacts 10 and 12 with a copper wire. Now the control unit is in the information output mode. Sit in the driver's seat and turn on the ignition, you will see the warning light flash. Your task is to count them.
The fault code consists of two or three digits. The number of flashes of the signaling device is equal to a digit, then a pause and the next digit.

For example, fault code 26 would be displayed like this:

• 2 short flashes, each lasting 0.5 seconds;
• A pause of 1.5 seconds, which means the transition to the next digit;
• 6 short flashes;
• A long pause of about 4 seconds, indicating the end of the code.

The control unit starts transmitting information from code 12, repeated three times. This shows the health of the diagnostic system. Then the fault code, it also repeats three times; then - move on to the next problem, if any. After listing all the codes in memory, the block will repeat all the information until you remove the jumper from the connector. So you can take your time and check again.

After determining the fault code, look at the table (you can print it out and carry it with you in the glove compartment). You will immediately see what exactly does not work. If the memory is empty, only code 12 is transmitted.

Scheme of the device of the motor ZMZ 406

It should be noted that the failure of one of the sensors will not lead to engine shutdown (with the exception of the angular position sensor crankshaft, which is very unlikely to fail). If a malfunction occurs, the computer switches to an emergency program, the engine runs worse, but you can get to the workshop.

The ZMZ-406 engine and its modifications have been mass-produced in the industrial production of JSC "ZMZ" since 1996, designed for installation on cars GAZ brands, such as GAZ-31105, GAZ-3102 and "". Engine requires professional service due to the complex fuel supply system and electronic system management.

Characteristics of the engine ZMZ-406 2.3 16V Volga, Gazelle, Sable

Parameter	Meaning
Configuration	L
Number of cylinders	4
Volume, l	2,280
Cylinder diameter, mm	92
Piston stroke, mm	86
Compression ratio	9,3
Number of valves per cylinder	4 (2-inlet; 2-outlet)
Gas distribution mechanism	DOHC
The order of operation of the cylinders	1-3-4-2
Rated engine power / at engine speed	106.6 kW - (145 hp) / 5200 rpm
Maximum torque / at revs	200.9 Nm / 4500 rpm
Supply system	distributed injection with microprocessor control
Recommended minimum octane number of gasoline	92
Environmental regulations	Euro 0
Weight, kg	192

Design

Four-stroke engine with an electronic fuel injection and ignition control system, with an in-line arrangement of cylinders and pistons rotating one common crankshaft, with an overhead arrangement of two camshafts... The engine has fluid system cooling of the closed type with forced circulation. Combined lubrication system: under pressure and spray.

Cylinder block

The ZMZ-406 cylinder block is cast from gray cast iron. On the upper plane of the cylinder block of the ZMZ-406 engine there are ten M14x1.5 threaded holes for mounting the cylinder head. In the lower part of the ZMZ-406 block there are five crankshaft main bearing supports.

When repairing cylinders, two repair sizes are provided: 1st and 2nd. With the same repair dimensions pistons and piston rings are produced.

Crankshaft

The crankshaft is cast from high-strength cast iron VCh60 (more durable in relation to VCh50), has a full support structure and eight counterweights (two counterweights for each crank for better unloading from centrifugal forces and bending moments).

Piston

Parameter	Meaning
Diameter, mm	92,0
Compression height, mm	38,0
The volume of the internal recess, ss	2,66
Weight, g	431

Pistons according to the outer diameter of the skirt and cylinders according to the inner diameter are sorted into two size groups (1st and 2nd). Piston pin floating type, outside diameter finger 22 mm, length - 64 mm. The whole finger is 121g.

GAZ 31105 with an injection engine ZMZ-406, like any other car, has its own characteristics. In the people, such a car is simply called the Volga. The features of this car are associated not only with external characteristics but also on the technical side.

This is how the ZMZ 406 engine installed on Gas 31105 looks like

Engine power system type 406 injector include:

Scheme of the device of the engine ZMZ 406 for Gas 31105

The power system was installed exactly the same as on. That is, she also had an outboard fuel pump. For model gas 31105, such a pump is installed using a bracket under the bottom. Activated after receiving a command from electrical circuit which is controlled by the engine. After that, fuel is supplied to the rail from the tank, gasoline passes through a fine filter.

On models 11 years old, a submersible fuel pump is installed. Such a system captures vapors better and reduces toxicity. The space above the car's fuel tank is connected to a vapor recovery system through a filter, which is a carbon-based device. Everything domestic cars good in their own way. It's a matter of taste here.

It looks like the head of the engine block ZMZ 406

The technical characteristics of all are quite high. Initially, the 3110 was considered the best, but it was replaced by a new one. Spending on the Volga is fully justified, but the price depends on what technical characteristics the car has.

Yes, you can add the best system... It is important to constantly check the carburetor, and also to prevent overheating if installed. This type of engine is considered the best for this model. Not recommended . This is due to the fact that it requires a lot of money. And repairs will generally cost more than the car itself. Therefore, the most optimal engine 406.

Installed motor ZMZ 406

Such an engine is produced at the Zavolzhsky Motor Plant, supplying components to. This is the best product in the entire line. Such an engine can be found on.

Read also

Suspension for GAZ-31105

When latest model Gazelle was updated and received the 406 engine, then the 402 was completely discontinued. Now it can only be found at private traders or at showdowns. For all the time injection engine 406 gained a lot of popularity. Until now, it is not inferior to modern motors. It has high rates of efficiency and reliability. Moreover, its cost is affordable for any car owner.

Path from 402 to 406

Unfortunately, the 402 engine had a number of shortcomings that have been tried to be eliminated over time. For example, he constantly overheated. Most often, cases of overheating were observed in summer time... The car began to boil, the engine needed repair. All shortcomings were corrected later. During the reconstruction new model 406. This model was similar to the previous ones, but differed in higher strength.

The most important advantage is the injector. Fuel consumption has become much less. And in the winter, the engine picked up speed faster. In addition, the price has dropped significantly.

Reliability was a distinctive feature, so the model still occupies a leading position in the market. Engine repairs are carried out on mileage indicators of 200-300 km. However, the cost will be quite high. The engine has a diagnostic system that allows you to evaluate the operating margin.


Electronic devices are capable of outputting data, storing them and eliminating obsolete indicators. The operation of the motor is always under control. All malfunctions are coded, and their decoding is stored in service book... Those that are constantly repeated are deleted on their own. To find out about the data that the motor stores, you need to purchase a special tester. With it, you can display all the data on the computer. It is connected to the diagnostic connector block.

True, only specialists can do this. The cost is quite acceptable. Disconnecting the battery will erase all information. This should not be discounted. However, this fact does not affect the operation of the engine at all. The main thing is that the engine does not require any modifications and has a low. If fuel consumption becomes high, then you should look for the reason why this is happening.

Disassembled carburetor of the ZMZ 406 engine

It is possible that the whole thing is in the filters, which it is time to change. 406 engine attracts with its affordability and prevalence on sale. It can be found without problems at an attractive price. It does not require any additional investment. Reviews about him are positive. The owners of such a motor note that it is not capricious, reliable, durable. This can not but rejoice those who are going to buy it.

good enough modern engine with good technical characteristics. Produced by the Zavolzhsky Motor Plant. Unlike the previous model ZMZ engines, namely 402 already has 16 valves for 4 cylinders, a compression ratio of 9.3 and some more 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. The 406 injector engine has better specifications than its carbureted counterparts. With an equal mass (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 for 4061 and 4062. Such higher characteristics allow you to carry more cargo and more easily cope with bad roads.

It may seem that the fuel consumption of more powerful engine, that is, the injector 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 injection 406 engine is better, it has a rather complex power and control system, which 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 installed on domestic cars of the middle class. This engine was installed on a large number of GAZ cars and, in particular, on various versions of the Gazelle and Volga cars.