Engine "ZMZ-406 Turbo": description, specifications and reviews

2024 Author: Howard Calhoun | [email protected]. Last modified: 2023-12-17 10:16

The domestic engine "ZMZ-406 Turbo" is the successor of the classic analogue, known under the index 402. The new engine is somewhat reminiscent of the Swedish "Saab", the body of the unit is made of cast iron, the camshafts are on top. The power plant includes 16 valves, hydraulic compensators. This design allows the owner to get rid of frequent adjustment of the valves. The timing drive is equipped with a chain with a nominal service life of at least 100 thousand kilometers. Despite the simplicity of the design, the installation in question is much more "advanced" than its predecessor. Let's 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 issue - 1997-2008.
• Feeding part - injector/carburetor.
• Cylinder arrangement - in-line type.
• The number of cylinders and valves on each element is 4/4.
• Piston travel - 86 mm.
• Compression – 9, 3.
• The volume of the “engine” is 2286 cubic meters. see
• Power rating - 145 horsepower at 5200 rpm.
• Environmental standard - Euro-3.
• Weight - 187 kg.
• Fuel consumption in mixed mode - 13.5 liters per 100 km.
• The nominal working life of the unit is 150 thousand kilometers.
• Installation - "Volga" 3102/31029/3110, (Gazelle, Sobol).

Modifications

Several models of the ZMZ-406 Turbo engine were put into operation:

1. Carburetor modification 406. 1. 10. Used on Gazelles, consumes AI-76 gasoline.
2. Version 406. 2. 10. Injection motor, installed on Gazelles and Volga.
3. Model 406. 3. 10. Used on Gazelles (AI-92).

Main malfunctions

The ZMZ-406 Turbo engine is most often subject to the following malfunctions:

• Hydraulic timing chain tensioners are susceptible to jamming. In this regard, there is extraneous noise, the absence of vibrations, 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. This problem is also not uncommon. As a rule, such a breakdown occurs due to a clogged radiator or thermostat failure. Initially, it is recommended to check the coolant level and the presence of air pockets in the system.
• Increased oil consumption. Most often, the ZMZ-406 Turbo KIT motor experiences this problem due to wear on the seals and oil scrapers on the valves. Also, a malfunction sometimes occurs due tothe fact that a gap is formed between the plate and the valve cover, through which oil leaks. To fix the problem, just remove the cover and treat the surface with sealant.

Miscellaneous problems

Among other frequently occurring malfunctions of the ZMZ-406 Turbo engine, the following can be noted:

• Traction failures are often observed due to failure of ignition coils. After replacing these elements, the performance of the motor is restored instantly.
• Knocking in the power unit. This problem occurs due to wear of the hydraulic compensators. According to the manufacturer, the service life of these parts is designed for at least 50 thousand kilometers.
• Wear of piston pins, pistons and connecting rod bearings, which also leads to extraneous sounds in the motor.
• The power unit is troit. In this case, check the spark plugs, coils and compression.
• There is a fading of the power unit. 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 the fuel pump are repeatedly observed. In general, the causes of malfunctions are typical for all domestic motors, including poor build quality. Nevertheless, the 406th model is much more efficient and practical than its predecessor, number 402. For reference: on the basis of the 406th ZMZ, engines of the 405th and 409th series, with a volume of 2.7 liters, were developed.

Forcing

One of the optionsincreasing the power of the unit is an 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 chambers are being finalized, the size of the channels is increasing. At the next stage of improvement of the ZMZ-406 Turbo motor, lightweight T-shaped valves, springs of the 21083 type and new shafts, for example, from OKB 38/38, are being installed.

It doesn't make sense to use a standard tractor piston group. They acquire new forged pistons, a lightweight crankshaft. The node is balanced. The direct-flow exhaust is adjusted on a pipe with a diameter of 63 mm. As a result, the power will 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 a supercharger. In order for the device to withstand high pressure normally, a reinforced piston block should be installed. The rest of the design is identical to the conversions carried out during the atmospheric upgrade.

A Garrett 28 type turbine is mounted with a corresponding manifold, piping, intercooler, 630 cc injectors, 76 mm exhaust system, DBP + DTV. The output power as a result will be at least 300 “horses”. If desired, you can change the nozzles to the 800 cc configuration, which will further increase engine power, however, such a system will lead to rapid wear of the unit. Requires new installationcompressor, 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 ZMZ-406 Euro-2 Turbo timing kit is one of the most important points affecting the parameters of the power plant. In the system under consideration, wave processes occur that are tuned to a specific range of revolutions. In the standard version, the unit has ambiguous characteristics.

The pluses include a short intake tract, designed for high speed. On the other hand, the inlets on the filter have a rather small section. The filter element itself is high performance and does not need to be replaced with a zero option, which is difficult to maintain and does not have high efficiency.

To improve performance and fill the cylinders at high RPM, 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 with this.

Alternatively, you can not fence off anything under the hood, but bring the air intake under the bumper. However, in this case, there is a danger of receiving water hammer, while there is a slight decrease inmotor power.

Cylinder head revision

This operation is reduced to grinding the channels, smoothing out all sharp residues in the combustion chamber and on the bottom of the piston. For the engines in question, it is recommended to install a cylinder head gasket from unit 405.22 (Euro-3). It is made of solid metal, is more reliable and thin. As a result, it allows to increase the compression and efficiency of the engine.

The next step is to install camshafts with increased valve travel. For regular operation of the power plant in urban conditions, experts advise using a pair of shafts of type 30/34.

Other ways to upgrade

You can also improve the motor by installing the ZMZ-406 Euro2 Turbo timing kit. 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 pin offset by 4 mm are used with the new crankshaft. It should not leave the plane of the block and hit the cylinder head.

A good option for the power units of this model is the use of pistons with thin rings. They will reduce dynamic losses, which is especially important for resourceful engines. Alternatively, you can lighten the piston and connecting rod groups, but this will not have much effect on motors with a speed of up to 7 thousand revolutions per minute. Reducing the flywheel mass on such samples leads to intermittent operation, a rapid increase in speed andthe same intense drop. This is not very convenient, especially when moving around the city.

Reviews

As evidenced by user feedback, the ZMZ-406 motor is much better than its predecessor in terms of power and operation. However, it is not without its shortcomings. 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 modifications, since excessive implementations increase the characteristics of the installation, but also lead to rapid wear. Here you need to correctly compare the resulting effect and the estimated working resource. It should be noted that after 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.