The products of the Zavolzhsky Motor Plant are known in the automotive market of our region. The enterprise produces the ZMZ 405 engine, with a volume of 2.2 - 4.6 liters. Motors are installed on GAZ, PAZ, Fiat and other vehicles. Today, the plant has launched the production of automotive components, commissioned by global manufacturers Ford and ZF-Kama.
The products of the ZMZ 405 engine family are gasoline power plants with four cylinders arranged in a row, each cylinder has 16 valves. The modification is popular, it is used on Volga, Sobol, Gazelle cars. The engine is considered reliable, with an increased resource.
Fiat Ducato:
Description of the ZMZ 405 engine
Before the ZMZ 405 engine appeared, the company produced 402 and 406 series of power plants. These engines are outdated, which was the reason to develop a new generation of gasoline units that are superior to their predecessors.
Modification of the 406 power plant, unlike the 405 unit, is equipped with pistons with a large diameter (95.5 mm versus 92 mm), strong bridges that separate the cylinders, and special voids that remove excess engine heat. The connecting rods and other structural elements did not change. Power with an increase in volume also increased by seven horsepower, and increased torque. The remaining mechanisms and components are similar to their predecessor. The power plant subsequently served as the basis for the creation of the 409 version.
Today, the 405 engine serves GAZ and UAZ vehicles, this is a unit on which an injector is installed, due to which fuel consumption has decreased. Compared to the base engine used before the appearance of the model, the installation is distinguished by a sixteen valve head, in addition, a carburetor was installed on the four hundred and sixth. Today, ZMZ model 405 power plants meet Euro requirements, which made it possible to bring products to the sales level when the mechanisms are used for operation on foreign vehicles. The first imported car, which in 2011 began to put the engine, Fiat Ducato.
The plant being developed is intended for operation in moderate climatic conditions. The temperature at which the motor is used varies: -45°C to +40°C. If the temperature does not exceed 25 ° C, then the engine is not afraid of 100% humidity. According to GOST 15150, this version is classified as "U2".
As for the base unit: a four-cylinder gasoline engine performs four cycles during operation, the cylinders are arranged in a row, there are four valves for each cylinder. The valve drive is carried out by camshafts, the location of the latter is upper, one product is responsible for the intake valves, the second product is responsible for the exhaust valves. In vehicles GAZ - 3302, Gazelle, Sobol, the installation is placed longitudinally in the space under the hood, fastened with rubber supports, of which there are three in the kit. The motor is powered by an injector, the injection is distributed.
Motor characteristics
A feature of this power plant was a sixteen-valve cylinder head with two camshafts, separate fuel injection for each cylinder, hydraulic compensators for thermal gaps in the gas distribution mechanism.
Maximum power is 140 horsepower with a displacement of 2464 cu. see Stroke - 86 mm, cylinder diameter - 95.5 mm. The torque of this engine is 214 Nm at 4200 rpm. Sufficiently high aggregate indicators provided this model with high success and popularity. This unit is installed on the Volga, as well as on the Gazelle, Sobol and the Business modification. Thus, ZMZ-405 motors are installed on almost all modern models of the Gorky Automobile Plant.
405 engine models
Dozens of modifications have been produced on the basis of the power plant. The motors are equipped with a microprocessor controller of the engine control mechanism and an electronic control unit. The difference lies in the element models. Models 405 Euro 2 injector engine from the thirteenth year are converted to the third Euro requirement.
Modifications:
| Changes | Machine description | Cars |
| 4052.10 | Basic unit. | GAS |
| 40522.10 | Coincides with the base, answers "Euro-2". | GAS |
| 40524.10 | Coincides with the base, answers "Euro-3". | GAS |
| 40525.10 | Coincides with the base, answers "Euro-3". | GAS |
| 4054.10 | Modified model with turbine and compressor. | UAZ |
| 405220 | Base analog, complete with Mikas 7.1 electronic control unit | GAS |
| 40522R | The kit includes an electronic control unit "Mikas 11", a quick-release connection for fuel wires and a sealed connector for the ignition coil. | GAS |
ZMZ engine, model 4054.10:
Modifications of the Gazelle 405 engine with improved performance received an improved valve cover, a purge device that supplies the remains of burnt fuel to the receiver, catalyst. In addition, the operation of the gas distribution mechanism is provided by a chain device.
GAZ 3302 GAZelle with ZMZ 405 engine:
Modifications
The ZMZ-405 family consists of several engines that differ only in compliance with toxicity standards.
There are the following types of power plants:
- ZMZ-40522.10. Toxicity according to the standards - "Euro-2". Also installed on the "Gazelle" and "Volga".
- ZMZ-40524.10 and 40525.10 comply with Euro-3 emission standards. They are also put on cars of the Volga and Gazelle brands.
Specifications 405 engine
Engines of the ZMZ 405, 406 and 409 series received similar technical characteristics. This is not surprising, since the 406 modification served as the basis for the installations. The height of the core did not change, the connecting rods of the modifications remained the same, in the 409 model a crankshaft with an increased stroke was used (instead of 86mm 94mm), the pistons were shifted by four millimeters.
Technical data 405:
| clarification | Index |
| Purpose of the unit | GAZ, UAZ |
| Fuel | Petrol |
| How many bars | «4» |
| Assembly Block Alloy | Cast iron |
| Volume displacement chamber (pcs.) | «4» |
| Camera placement | row, vertical |
| Valve, total (pieces) | «16» |
| Volume 405 (l.) | 2,46 |
| How the move works | «1» + «3» + «4» + «2» |
| Displacement chamber, diameter (mm) | 95,5 |
| Distance between extreme positions of the piston (mm.) | 86 |
| Piston space ratio at TDC/BDC | 9,3 |
| Power (hp) | 152 |
| Crankshaft rotation force (Nm) | 211 |
| Weight, kg.) | 192,2 |
| Service life (km.) | 250000 |
| Lubricant application system | pressure + steam |
| Oil volume in 405 engine (l) | 6 |
| Oil for the unit | 5W-30 (40), 10W-30 (40) |
| Liquid cooling | closed, ventilation |
| Cooling liquid, quantity (l.) | 10 |
Peculiarities
ZMZ 405, the engine, has been repeatedly refined and updated, the version with an injector that meets the Euro 3 standard turned out to be massive and in demand. The solutions that the unit was equipped with are as follows:
The head of the unit block has lost the idle mechanism.
- This made it possible to reduce weight and fasten the unit with bolts of a long design.
Cylinder head ZMZ 405:
- The seal of the head of the block of the unit was replaced with a gasket consisting of two layers. The use of a metal seal made it possible to increase the ability to hold the increased pressure of gases, to prevent leakage of oil and liquid from the unit.
Cylinder Head Gasket:
- Engine 405 "Euro 3", resistant to forces that cause deformation. The rigidity of the frame structure is achieved due to the need to tighten the unit with bolts.
- The control is carried out by the accelerator electronics. Elimination of most of the structural elements of the unit, for example, the idle unit, air ducts, accelerator pipes, position sensors, etc.
ZMZ 405 throttle assembly:
- Added a bearing capable of automatically tensioning the drive belt.
ZMZ 405 tension roller:
- Elimination of low tides in the space of the unit. It made it possible to make the block even stronger, in addition, transverse slots were used, which increased the cooling of the unit. The Gazelle car, operating the 405 engine, received increased reliability and durability. The decrease in toxicity standards made a breakthrough for the use of the unit in the international market.
Engine malfunctions
The process of operating the power plant revealed the following design flaws, which manifest themselves with improper care and operation of the unit:
- Malfunctions in the hydraulic tensioning mechanism of the timing chain. Jamming often occurs, which leads to the destruction of the shoe and the chain jumping. The first sign is the presence of noise.
- The unit overheats frequently. Cause of overheating, clogged radiator, defective bypass valve, or improper coolant level in the cooling device.
- Increased lubricant consumption in the unit. The cause of the malfunction, oil scraper rings and valve seals. There may also be malfunctions in the oil deflectors and fluid outlet pipes. Remove valve cover and treat with sealing grease.
- Interruptions in idling, loss of power by the unit. The cause of a malfunction in the electrical circuit of the car. Failure of the ignition coil.
Typical malfunctions and problems
Due to the fact that this engine is the result of the modernization of the ZMZ-406, many weak points have migrated to the new unit. Therefore, often the problems for both motors are the same.
Let's look at them:
- Timing chain tensioners. They wedged over time, so that the vibrations of the chain are not damped. This becomes audible from the increased noise. The shoe tightens the chain worse. Over time, the latter can jump to the tooth, which will soon lead to costly repairs.
- Despite the improved gasket and modified block channels, the motor is still prone to overheating. The reason for this may be the thermostat or the radiator of the cooling system.
- High engine oil consumption can be caused by two reasons. The first is oil scraper rings and valve seals. The second reason is a leak in the same place as the ZMZ-406 - from under the valve cover. To be more precise - in the place where the cover of the oil separator plates fits.
- Engine stalling and rough idling can be caused by ignition coils. Usually with their replacement the problem disappears.
- Knocking in the engine often appears due to wear of the thermal gap hydraulic compensators. Their resource is small, about 50 thousand kilometers. If, after replacing them, the knock remains, then there can be quite a few reasons, up to the wear of the piston group.
In addition, various “glitches”, electrical malfunctions, were inherited from the ZMZ-406. The ZMZ-405 sensors and the unstable operation of the fuel pump also contribute to the reputation of this engine. Poor build quality, unfortunately, did not bypass this power unit.
But ZMZ-405 is no worse than the 406th. Improvements are, and they were needed. About ZMZ-402, we can say that this is a veteran of the Russian engine building. With proper care, maintenance and a calm driving style, the unit can withstand at least 300 thousand kilometers. Such cases are not uncommon, especially when operating Gazelle ZMZ-405 light trucks.
Tuning 405 engine
For those who lack the dynamics and power of a regular power unit, they improve the characteristics of the installation by refining the engine.
You can act on this unit in three scenarios:
Forcing the unit
- Simple modernization, refinement of the motor, without changing the atmospheric status. To do this, the installation is completed with shafts. Tuning the intake: install a cold air intake, a receiver. They finalize the working chamber, increase the diameter of the channels, install lightweight valves, springs, shafts. The regular piston group is not suitable for modernization, so they buy forged pistons, lightweight connecting rods, and a crankshaft. These works increase power, the unit produces up to two hundred horsepower.
Refinement of ZMZ 405, reinforced springs 21083:
Equipment of the unit with a turbine compressor.
- For this method, tuning can only be done with the Euro 3 block, since the Euro 2 block is not suitable for this purpose, since it is weakened by cooling cavities. For successful transfer of loads and pressure, the unit is equipped with a forged piston group. A turbine is installed, a collector is selected under it, pipes are mounted, a cooler is installed. After such refinement, the output is 300 horsepower.
Refinement of ZMZ 405, Garett 28 turbine:
