GAZelle vehicles are equipped with UMZ and ZMZ engines, however, in recent years, power units of the ZMZ-406 series have been given the greatest preference. One of the most modern motors in this line is the ZMZ-40630A - its design, characteristics, features and maintenance are described in the article.

General view of the ZMZ-40630A engine

The ZMZ-406 engine line has been produced by the Zavolzhsky Motor Plant since 1997, during which time the power unit has received the widest distribution (more than one and a half million units have been manufactured), fame and popularity among motorists. The current engine modifications have gone far from the original 406 engine, they have excellent performance, high reliability and quality, thanks to which they have won a serious market share.

ZMZ-40630A is one of the latest engine modifications with improved performance. This is a carbureted four-cylinder in-line engine with a working volume of 2.3 liters and a power of 98 hp, designed for the use of A-92 (AI-93) gasoline. The gas distribution mechanism of the motor is a two-shaft 16-valve, both shafts are located in the upper part of the cylinder head. The motor is equipped with a modern microprocessor ignition system. The power unit is equipped with a K-151D carburetor, which replaced the early Solexes.

Engine ZMZ 406 2.3 l.

Characteristics of the ZMZ-406 engine

Production	ZMZ
Engine brand	ZMZ-406
Release years	1997-2008
Block material	cast iron
Supply system	injector/carburetor
Type	in-line
Number of cylinders	4
Valves per cylinder	4
Piston stroke, mm	86
Cylinder diameter, mm	92
Compression ratio	9.3 8*
Engine volume, cc	2286
Engine power, hp / rpm	100/4500* 110/4500** 145/5200
Torque, Nm/rpm	177/3500* 186/3500** 201/4000
Fuel	92 76*
Environmental regulations	Euro 3
Engine weight, kg	185* 185** 187
Fuel consumption, l/100 km - city - track - mixed.	13.5 — —
Oil consumption, g/1000 km	up to 100
Engine oil	5W-30 5W-40 10W-30 10W-40 15W-40 20W-40
How much oil is in the engine	6
When replacing pour, l	5.4
Oil change is carried out, km	7000
Operating temperature of the engine, hail.	~90
Engine resource, thousand km - according to the plant - on practice	150 300+
tuning — potential - no loss of resource	600 + up to 200
The engine was installed	GAZ 3102 GAZ 31029 GAZ 3110 GAZ 31105 GAZ Gazelle GAZ Sobol

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

Faults and engine repair Volga / Gazelle ZMZ-406

The ZMZ-406 engine is the successor to the classic ZMZ-402, a completely new engine (albeit made with an eye on the Saab B-234), in a new cast-iron block, with an overhead camshaft, the latter are now two and, accordingly, the 16 valve engine. Hydraulic compensators appeared on the 406 and fuss with constant valve adjustment does not threaten you. The timing drive uses a chain that needs to be replaced every 100,000 km, in fact, it runs more than 200 thousand, and sometimes it doesn’t reach 100, so once every 50 thousand km you need to monitor the condition of the chain, dampers and hydraulic tensioners, tensioners, usually very poor quality.
Despite the fact that the engine is simple, without variable valve timing and other modern technologies, for GAZ, this is a big progress in relation to the 402 engine.

Engine modifications ZMZ 406

1. ZMZ 4061.10 - carburetor engine, SZh 8 for 76th gasoline. Used on Gazelle.
2. ZMZ 4062.10 - injection engine. The main modification is used on the Volga and Gazelle.
3. ZMZ 4063.10 - carburetor engine, SZh 9.3 for 92nd gasoline. Used on Gazelle.

Malfunctions of engines ZMZ 406

1. Timing chain tensioners. It tends to jam, as a result of which the absence of vibrations is not ensured, chain noise occurs, followed by the destruction of the shoe, the chain jumping, and perhaps even its destruction. In this case, ZMZ-406 has an advantage, it does not bend the valve.
2. Overheating ZMZ-406. A common problem, usually the thermostat and a clogged radiator are to blame, check the amount of coolant, if everything is in order, then look for air pockets in the cooling system.
3. High oil consumption. Usually it's the oil scraper rings and valve seals. The second reason is a labyrinth oil deflector with rubber tubes for oil drainage, if there is a gap between the valve cover and the labyrinth plate, then oil leaves here. The cover is removed, smeared with sealant and there are no problems.
4. Traction dips, uneven XX, these are all dying ignition coils. On ZMZ-406 this is not uncommon, change and the motor will fly.
5. Knocking in the engine. Usually in the 406th hydraulic lifters knock and ask for a replacement, they go about 50,000 km. If they are not, then there are a lot of options, from piston pins to pistons, connecting rod bearings, etc., an autopsy will show.
6. Engine troit. Look at spark plugs, coils, measure compression.
7. ZMZ 406 stalls. The point, most often, is in the BB wires, the crankshaft sensor or the IAC, check.

In addition, sensors are constantly buggy, poor quality electronics, there are problems with the fuel pump, etc. Despite this, the ZMZ 406 is a giant step forward (compared to the outdated ZMZ-402 design), the engine has become more modern, the resource has not gone away and, with adequate maintenance, timely oil changes and a calm driving style, can exceed 300 thousand .km
In 2000, on the basis of the ZMZ-406, the ZMZ-405 engine was developed, and later a 2.7 liter ZMZ-409 appeared, a separate one about it.

Engine tuning Volga / Gazelle ZMZ-406

Forcing ZMZ 406

The first option for increasing engine power, according to tradition, is atmospheric, which means we will install shafts. Let's start with the intake, put in a cold air intake, a larger receiver, cut the cylinder head, modify the combustion chambers, increase the diameter of the channels, grind, put the appropriate, lightweight T-shaped, valves, springs 21083 (for evil options from BMW), shafts (for example, OKB Engine 38/38). It makes no sense to turn a regular, tractor piston, so we buy forged pistons, light connecting rods, a lightweight crankshaft, and balance it. Exhaust on a 63 mm pipe, straight-through and all this is set up online. The output power is approximately up to 200 hp, and the character of the motor will receive a pronounced sporty shade.

ZMZ-406 Turbo. Compressor

If 200 hp. If you're looking for childish fun and want real fire, then supercharging is the way to go. In order for the motor to normally endure high pressure, we will put a reinforced forged piston group under low CV ~ 8, otherwise the configuration is similar to the atmospheric version. Turbine Garrett 28, manifold for it, piping, intercooler, injectors 630cc, exhaust 76mm, DBP + DTV, setting in January. At the output, we have about 300-350 hp.
You can change the nozzles to more efficient ones (from 800cc), install Garrett 35 and blow until the engine falls apart, so you can blow out 400 or more hp.
As for the compressor, everything is similar to turbocharging, but instead of a turbine, manifolds, pipes, intercooler, we put a compressor (for example, Eaton M90), tune in and go. The power of the compressor options is lower, but the motor is trouble-free and pulls from the bottom.

The 406 engine has been in production since 1996. He managed to establish himself as a simple and fairly reliable power unit. In terms of reliability, this engine is not inferior, and in some cases exceeds 402. This engine is the real pride of the plant.

History of creation

The first prototypes of the unit appeared in 1982-84. It was a planned development of NIIT "AvtoProm". During the construction of the 406, Soviet engineers took the sports Saab 900 as a basis. A little later, foreign workers remade the Saab a little, but there are similarities.

In 1990, the 406 engine was already fully constructed. It has finally found its final form. In 1992, a special workshop was launched at ZMZ, where a new family of engines was produced in small batches.

The first experimental prototypes of engines of this family were installed on small patrol boats. Then the 406th seriously interested the workers of GAZ. In March 1996, Volga and Gazelle began to be equipped with these units.

Design

So, the 406 engine is a 16-valve, four-cylinder, in-line gasoline engine. It was equipped with an electronic injection control system. As mentioned above, they were installed on GAZ 3110 and 3302 cars.

This engine has design features. These are camshafts located at the top in the cylinder head. Each cylinder had 4 valves. Engineers have significantly increased the compression ratio. Now it was 9.3. This was achieved by replacing the combustion chamber with centrally located spark plugs and by using a new injection system. Even in the new engine, the usual carburetor power system was replaced.

So, it was possible to significantly increase the power and torque of this unit. At the same time, fuel consumption has decreased, and exhaust toxicity has also decreased. However, among motorists and in articles that were published in reputable automotive magazines, there were rumors and information slipped that the power of the Volga 406 car (the ZMZ engine was also installed on it) was artificially overestimated.

Design features

To make the operation of this power unit more reliable after the increase in power, the following design features were applied by engineers. Let's take a look at them.

Cylinder block

It was made by casting from cast iron, and not from aluminum, as in previous versions. The head of the 406 engine did not have insert sleeves, but was distinguished by higher rigidity, stable clearances. Engineers deliberately reduced the piston stroke to 86 mm. The mass of the piston and pin was also reduced. For their manufacture, more modern and technologically advanced materials were used. Also, the crankshaft, connecting rods and other parts were made from high-quality materials.

Camshaft drive

It is a chain drive failure, equipped with automatic hydraulic tensioners. In the valve mechanism, the designers used hydraulic pushers. Now there is no need for constant adjustment of the gaps.

However, the hydraulics, and the fact that the 406 engine is now uprated, require the use of a better oil. Therefore, now the motor is equipped with an improved oil filter with additional elements for cleaning.

Control system

The complex control of the unit has the functions of controlling the ignition, and also makes it possible to more accurately dose the fuel supply and adjust the ignition angle. Now, with various operating modes, you can get optimal performance in terms of power, efficiency and toxicity.

Engine 406: specifications

So, as already mentioned, this is a gasoline 4-stroke in-line engine. The cylinder diameter is 90 mm. The cylinders have a volume of 2.3 liters. The compression ratio of the engine is 9.3. The cylinders work in the order 1-3-4-2. The crankshaft rotates to the right. The power that this engine is capable of is 110 hp. With. The engine runs on 92-octane gasoline. The power system is carried out by injection into the pipe.

The lubrication system in this unit is combined. Oil is sprayed onto the friction parts forcibly, under pressure. Motor cooling - liquid, forced.

Carburetor or injector?

Many drivers are faced with a choice between two options. This is because old designs are being replaced by new fuel injected engines everywhere. The 406th and 405th units are put on heavy vehicles. They are equipped with "Volga", UAZ, "Gazelle". These cars need power, and this motor can provide it.

Disadvantages of a carburetor

If we compare the 406 engine (carburetor) and its injection relative, then the first one will noticeably lose in terms of power and performance. It's all about the carburetor power system. In this case, the fuel enters the cylinders not forcibly, but as the speed increases. That is why such units have lower power and acceleration characteristics than their injection counterparts. On such internal combustion engines, power is supplied by a forced scheme. At the same time, the injection dose is as accurate as possible. It is calculated electronically. And here the fuel will go directly into the cylinders. If you force the throttle to open as sharply as possible, then the mixture will not become poorer, as it would be with a carburetor. This allows us to talk about the best dynamic qualities.

In addition, the 406 engine (carburetor), according to drivers and owners, is economical. In this case, it is very difficult to adjust the exact dosage of fuel. Many seriously believe that this is almost impossible. In different modes, a different mixture of fuel and air will be supplied to the unit. This will lead to a decrease in power and increased consumption.

However, despite all the negative qualities, this engine also has advantages. This is the reliability of the carburetor. The maximum that can happen to him is clogging. So, it will not be difficult to disassemble and clean the jets, wherever the car is.

Advantages of the injector

As you can see, the 406 injector engine is far superior to its carbureted counterpart in terms of power and economy. However, the main advantage of just such an installation is reliability.

These motors do not need to be adjusted. They don't often refuse to work. There are no jets as a class, so nothing will clog in the power system. Fuel will flow directly into the cylinders. In addition, it is very economical.

But even here, not everything is so good and rosy. The injector has its pitfalls. If the car breaks down on the way, the driver is unlikely to be able to fix it on his own. Numerous reviews speak of this.

The operation of such motors is fully controlled by electronics. Therefore, in the event of failure of at least one of the sensors, this will necessarily affect the performance of the motor. Of course, if it is possible to install imported elements and regularly carry out maintenance, then the 406 engine (injector) will only please its owner.

Major failures and maintainability

The engine is quite maintainable, like all products of the Zavolzhsky plant. The crankshaft can be ground, the cylinder block can be bored. The cast iron head is no longer so sensitive to low-quality antifreeze.

Like many modern power units, this motor requires only high-quality oil. Its design is made in such a way that the unit itself has become very picky. Many drivers often complain about the increased oil consumption on such engines.

Repair of a 406 engine is a costly and very serious matter. Many motorists prefer to give it to specialists. However, all work on the repair of this unit is described in detail in many articles and books.

Conclusion

Although the 406 motors are no longer produced, they will be used for a very long time. After all, it was this engine that was serially installed on such cars as the Volga and Gazelle. Therefore, its relevance will not fade for at least the next 10 years.

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.

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. The injection system, which was later replaced by a carburetor, was able to correct the situation a little - 201 Nm and 145 hp. s., respectively.

Specifications ZMZ 406 2.3 l / 100 l. With.

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

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

After the changes made, the technical characteristics of ZMZ 406 correspond to the values ​​\u200b\u200bgiven in the table:

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

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

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

Design features

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

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

Reliability is enhanced by a cast-iron cylinder block without liners, a reduction in piston stroke to 86 mm and the weight of the entire group of SHPGs. Bolted connecting rods, crankshaft and piston rings are made from high strength materials, so major repairs are less frequently required.

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

List of engine modifications

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

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

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

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

Advantages and disadvantages

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

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

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

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

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.

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.

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

Overview of faults and how to fix them

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

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

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

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

Motor tuning options

Initially, the ZMZ 406 engine allows you to increase the power on your own up to 200 - 250 hp. 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).

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

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

If you have any questions - leave them in the comments below the article. We or our visitors will be happy to answer them.

A good, fairly modern engine with good technical characteristics. Produced by the Zavolzhsky Motor Plant. Unlike the previous model of ZMZ engines, namely 402, it 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 the 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 a more powerful engine, that is, a fuel-injected 406, should be greater. But no. Fuel consumption is substantially 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 is installed on domestic middle-class cars. This engine was installed on a large number of GAZ cars and, in particular, on various versions of the Gazelle and Volga cars.