The domestic engine "ZMZ-406 Turbo" is the receiver of the classic analog known under the index 402. The new motor is somewhat reminiscent of the Swedish "Saab", the unit body is made of cast iron, the camshafts are located on the top. The power plant includes 16 valves, hydraulic compensators. This design allows the owner to get rid of frequent valve adjustments. The timing drive is equipped with a chain, the nominal service life of which is at least 100 thousand kilometers. Despite the simplicity of the design, the installation in question is much more “advanced” than its predecessor. We will study the features of the device and user reviews about it.
"ZMZ-406 Turbo": characteristics
Below are the parameters of the motor in question:
- Years of production - 1997-2008.
- The supply part is an injector / carburetor.
- The arrangement of the cylinders is in-line type.
- The number of cylinders and valves on each element is 4/4.
- The movement of the piston is 86 mm.
- Compression - 9.3.
- The volume of the "engine" is 2286 cubic meters. cm.
- Power indicator - 145 horsepower at 5200 rpm.
- The environmental standard is Euro-3.
- Weight - 187 kg.
- Combined fuel consumption is 13.5 liters per 100 km.
- The nominal working life of the unit is 150 thousand kilometers.
- Installation - "Volga" 3102/31029/3110, (Gazelle, Sable).
Modifications
Several models of the ZMZ-406 Turbo engine came into operation:
- Carburetor modification 406. 1. 10. It is used on "Gazelles", consumes AI-76 gasoline.
- Version 406. 2. 10. Injection motor, installed on the "Gazelle" and "Volga".
- Model 406. 3. 10. It is applied on "Gazelle" (AI-92).
Major malfunctions
The ZMZ-406 Turbo engine is most often subject to the following malfunctions:
- The hydraulic tensioning mechanisms of the timing chain are jammed. In this regard, extraneous noise arises, the absence of oscillations, further deformation of the shoe, up to the destruction of the entire chain. In this regard, the advantage of the engine in question is that the valves do not bend on it.
- Overheating of the power plant. A similar problem is also not uncommon. As a rule, such a breakdown occurs due to a clogged radiator or failure of the thermostat. Initially, it is recommended to check the coolant level and the presence of air locks in the system.
- Increased oil consumption. Most often, the ZMZ-406 Turbo KIT motor experiences this problem due to wear of the oil seals and oil scraper valves. Also, a malfunction sometimes occurs due to the fact that a gap is formed between the plate and the valve cover through which oil leakage occurs. To fix the problem, it is enough to remove the cover and treat the surface with sealant.
Other issues
Among other frequently occurring malfunctions of the ZMZ-406 Turbo engine, the following can be noted:
- Often there are draft failures due to failure of the ignition coils. After replacing these elements, the motor is restored immediately.
- A knock on the powertrain. This problem occurs due to wear on the hydraulic expansion joints. According to the manufacturer, the service life of these parts is designed for at least 50 thousand kilometers.
- Deterioration of piston pins, pistons and connecting rod bearings, which also leads to the appearance of extraneous sounds in the motor.
- The powertrain troit. In this case, check candles, coils and compression.
- The power unit is fading. Most often, "ZMZ-406 Turbo" stalls due to a malfunction of the wires, crankshaft sensor or IAC.
In addition, failures in the operation of the ZMZ-406 Turbo clutch and gasoline pump are repeatedly observed. In general, the causes of malfunctions are characteristic of all domestic engines, including poor build quality. Nevertheless, the 406th model is much more efficient and practical than its predecessor under number 402. For reference: on the basis of the 406th ZMZ, the engines of the 405th and 409th series were developed, with a volume of 2.7 liters.
Boost
One option for increasing the power of the unit is the atmospheric method with the installation of additional shafts. At the inlet, a cold air intake is mounted, a receiver with an increased diameter. Then the cylinder head is sawn, the combustion compartments are finalized, the size of the channels increases. At the next stage of improvement of the ZMZ-406 Turbo motor, lightweight T-valves, 21083 series springs and new shafts are installed, for example, from OKB 38/38.
Use a standard tractor piston group does not make sense. New forged pistons and lightweight crankshaft are purchased. Balance the node. Direct-flow exhaust is configured on a pipe with a diameter of 63 mm. As a result, the power will turn out to be about 200 horsepower, and the characteristics of the power plant will have a pronounced sports configuration.
ZMZ-406 Turbo: tuning
The second way to improve the engine in question is to install boost. In order for the device to tolerate high pressure normally, a reinforced piston block should be installed. The rest of the design is identical to the transformations carried out during atmospheric modernization.
Mounted turbine type Garrett 28 with the appropriate manifold, piping, intercooler, 630 cc nozzles, 76 mm exhaust system, DBP + DTV. The output power as a result will be at least 300 “horses”. If desired, the nozzles can be changed to a configuration of 800 cc, which will further increase engine power, however, such a system will lead to rapid wear of the unit. It will require the installation of a new compressor, such as the Eaton M90. Then you need to fine-tune it. As practice shows, such an upgrade allows you to get a motor without failures, the thrust of which is already felt from the bottom.
Intake system configuration
This operation using the new timing kit “ZMZ-406 Euro-2 Turbo” is one of the most important moments affecting the parameters of the power plant. In the system under consideration, wave processes occur that are tuned to a specific speed range. In the standard version, the node has ambiguous characteristics.
The pluses include a short intake tract, designed for high revving. On the other hand, the inlets on the filter have a rather small cross section. The filter element itself is characterized by high performance and does not require replacement with the zero option, which is difficult to maintain and does not differ in high efficiency.
To improve performance and fill cylinders at high speeds, experts recommend removing the standard atmospheric filter housing. The solution to this problem is manifested in the installation of a "cold inlet" system. At the installation site of the air filter element, a closed volume is equipped in such a way that the air flow enters exclusively from the outside. An additional partition will help in this.
Alternatively, you can not block anything under the hood, but remove the air intake under the bumper. However, in this case, there is a danger of water hammer, while there is a slight decrease in motor power.
Refinement of the cylinder head
This operation comes down to grinding the channels, smoothing out all sharp residues in the combustion compartment and on the bottom of the piston. For the engines in question, it is recommended that the cylinder head gasket be installed from the 405.22 (Euro-3) unit. It is made of solid metal, is more reliable and thin. As a result, this allows you to increase compression and engine efficiency.
The next stage is the installation of camshafts with increased valve movement. For regular operation of the power plant in a city, experts advise using a pair of shafts of type 30/34.
Other ways to upgrade
It is also possible to improve the motor by installing the timing kit “ZMZ-406 Euro2 Turbo”. In addition, the crankshaft is mounted with an increased stroke of the crank assembly. This will make it possible to increase the working volume to 2.5 liters. Additionally, pistons with a finger shifted by 4 millimeters are used with the new crankshaft. He should not go out of the plane of the block and hit the cylinder head.
A good option for the power units of the model in question is the use of pistons with thin rings. They will reduce dynamic losses, which is especially true for revving engines. Alternatively, you can do the relief of the piston and connecting rod group, but this will not have much effect on motors with a speed of up to 7 thousand revolutions per minute. Reducing the mass of the flywheel on such samples leads to intermittent operation, a quick set of revolutions and the same intensive dropping. This is not very convenient, especially when moving in the city.
Reviews
According to user feedback, the ZMZ-406 motor is much better than its predecessor in terms of power and operation. However, he is not without flaws. In this regard, many owners are tuning the unit. How to do this was discussed above. The main thing is not to overdo it with improvements, since excessive implementations increase the characteristics of the installation, but also lead to quick wear. Here you need to competently compare the resulting effect and the estimated working resource. It is worth noting that after the modification of any motor, subsequent adjustment of its control system is required. The Molt program will help in adjusting a specific motor, which optimizes the operation of each engine, depending on its features.