Markers for setting the ignition on the 405 ZMZ timing engine

Manufacturers put timing marks on ZMZ 405 engines. These marks are needed in order to correctly align the crankshaft and camshaft after changing the chain in the distribution mechanism of the power unit. Because if installed incorrectly, the engine may fail. A major overhaul of the ZMZ 405 engine will be expensive for the car owner.

Engine timing marks 405-406-409

This article describes in detail all the timing marks located on the 405-406-409 engine.
It is explained how to set timing marks on these engines. How to set engine timing marks accompanied by photographs Timing marks are certain marks on engine parts that have different appearances and configurations. They are designed for precise installation of the ignition and gas distribution system, correct and accurate installation of engine shafts.

The marks are fixed on the front parts of the engine so that they are not erased during operation. These can be: risks, tides of different configurations, points, holes, pins, slots, and so on. Marks are applied to two adjacent parts of the unit.

Timing marks 405, 406, 409 of the engine are located outside and inside.

There are two timing marks located outside the power unit.

First timing mark

installed on the front cover of the cylinder block. It looks like a tide, in the form of a line.

Second timing mark

406, 405, 409 of the engine is located on the cardan damper pulley. It represents a deep groove on its rim.

When these two marks are combined, the piston of the first cylinder rises to its highest dead center. If this does not happen, then you must continue to rotate the cardan clockwise until the piston reaches TDC. This moment is a test.

In this case, the first cams of both camshafts should face in different directions:

If the tops of the cams are located inward, then turn the driveshaft one more turn.

Accurate alignment of the piston of the first pot at TDC can be done using a dial indicator, which is mounted in the spark plug hole of the first pot.

If there is no indicator, then you can use a long rod or a long screwdriver.

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Draining antifreeze from the system

First, prepare containers into which you will need to drain the liquids. First of all, empty the cooling system - there should be quite a lot of antifreeze, about 10 liters. To drain the antifreeze, you need to unscrew the plug located in the lower half of the radiator.

As soon as you unscrew the plug, the pressure will be very strong; as the level decreases, it will decrease. It is advisable to use a wide container so as not to lose liquid. In order for the antifreeze to drain faster, you need to unscrew the cap on the expansion tank, increasing the pressure in the system.

Mark on the crankshaft pulley ZMZ 406 which tooth

Hello All Dear Friends. I'll tell you how to set the timing phases of ZMZ 405,406,409 using split stars. The stars are sold together with the timing kit or can be purchased separately. The price is quite reasonable, and the benefits from them are enormous. Even in field conditions, you can carry out any manipulations with the timing belt. I’ll tell you using the example of ZMZ 405 euros 3. First of all, remove the valve cover.

Original

• Original1
• Analogs2
• How to distinguish a fake3
• Replacing the timing chain on the ZMZ-4054 ​​engine
• What is needed for replacement5
• Step-by-step process for replacing chains and other timing components6

Original parts last an order of magnitude longer than their counterparts. The main reason is high quality control. If the car is operated in difficult conditions, under heavy loads, it is advisable to opt for higher quality parts. The cost of the original chain is an order of magnitude higher than the analogue one.

How to set top dead center TDC.

First you need to set the top dead center, the so-called TDC. To do this, use a ratchet and a 24mm socket to rotate the crankshaft clockwise (it cannot be rotated counterclockwise). We saw a place on the crankshaft pulley where two teeth were missing.

We count 15 teeth counterclockwise. The fifteenth tooth should coincide with the mark on the pulley damper (if it has not been turned or moved). We combine this tooth with the ebb on the front timing chain cover. If the radiator is not removed, the ebb on the cover is difficult to see. I recommend ots

Where is the chain located

Getting to the timing chain is not so easy. A complete disassembly of the engine will be required. And this is a serious process. If the car owner does not understand the design of the timing belt, it is recommended to contact a service center. Let's take a look at the timing belt layout.

The belt itself is installed on the crankshaft and camshaft. When the pulley rotates, the rotation is then transmitted to the camshafts. And the tension is adjusted thanks to a damper inside the unit.

Similar article 126 VAZ engine bends the valve or not

If the operation of the damper is disrupted, the device is faulty, then the belt can jump from one to three or four teeth. The operation of the engine will be unstable, and wear on the unit will increase with every kilometer.

We set the timing phases.

Next we set the timing phases. Let's look at the camshafts. They should be turned with their fists in different directions. If they look at each other, then we make one more revolution of the crankshaft.

Next, loosen the bolts securing the camshaft stars. To set the phases I use this protractor.

My camshafts are different. Intake 240, outlet 252 and each has its own template. We install a protractor behind the first cam of the exhaust camshaft. Using the key, we turn the square on the camshaft body until the template arrow is at the 19 mark. In the same way, we set the intake mark to 20. A deviation of plus or minus two degrees is allowed. But the more accurately you set it, the better the dynamic performance of the engine will be. Next, tighten the bolts securing the camshaft stars to a torque of 4.6 ... 7.4 kgf.m.

If you changed the hydraulic chain tensioner, then after recharging it and installing it in place, make two turns of the crankshaft so that the chain takes the correct tensioned position. And only after that set the timing phases.

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Signs of breakdown of the gas distribution mechanism

Symptoms of a ZMZ timing belt failure include noise during idle speed. Fuel consumption increases. The timing system is not stable. Popping noises appear in the intake and exhaust manifolds. Beginners will ask the question: “Why is this happening? What can I do to optimize fuel consumption and get rid of noise?

If the thermal clearances of the ZMZ do not correspond to the norm in a certain phase, then the valves will not open and close when necessary. In this case, the hydraulic compensators break. Overheating negatively affects chains and gear teeth. Metal cracks, bursts and breaks.

If there are cracks and chips on the timing chain body, then only replacing the timing chain will help.

Mark on the crankshaft pulley ZMZ 406 which tooth

Hello! Today we’ll talk about how to set marks on the ZMZ 406 engine and modifications. In what cases are tags needed? The engine of the ZMZ family is equipped with hydraulic compensators and ignition coils, which means that there is no need to adjust the valves and ignition, and in this case we do not need ZMZ timing marks, there is only one thing left, this is the timing system, and in this case we change the entire set, or only the camshaft sprockets, I recommend installing split stars, it is more convenient and easier to set the phases. There are quite a lot of ways to set a mark; first you need to understand the condition of your engine and crankshaft pulley. Let's start with each method in order, so it will be more convenient to check these methods and not mix everything into a mess.

Placing a mark on the pulley

If we only change the camshaft sprockets, then we do not disassemble the bottom and set the lower mark of the crankshaft along the pulley; there is a shoulder on the front cover, and there is a mark on the pulley. We combine as in the photo.

Damper check

This method is only suitable if you have a normal pulley and the damper has not yet been turned. How can we check that the damper is not turned and that we are aligning the marks correctly? We count 15 teeth and align the mark on the front cover between the 15th and 16th teeth. Look at the photo:

And so we combined the mark at the bottom and now move on to the top part, installing the ZMZ timing marks on the camshaft sprockets. As we know, stars can be simple and cut.

Setting marks on camshaft sprockets

Setting marks on simple camshaft sprockets: In practice, in 95% of cases it was necessary to drill the sprockets along the jig and set the marks correctly so that the mark (small poke) on the sprocket coincided with the cylinder head. Look at the photo:

The task becomes easier when you have split sprockets and now you don’t need to align the marks and drill, you just need to set the camshaft correctly. If we are facing the engine, then we need to set 19 degrees on the right camshaft, and 20 degrees on the left. Look at the photo:

After setting the camshaft degrees, tighten and install the chain tensioner, crank the engine and check the marks again, if everything matches, safely assemble the engine and enjoy the ride.

Crankshaft star mark

When we change the entire timing belt set, pay attention to the lower sprocket; there is a mark on it; when installing, align this mark with the mark on the engine. Look at the photo:

Setting the wash mark

The intermediate star is also set according to the mark, but as practice shows, it does not play any role and it is not clear why it is needed there. The most important thing is to align the bottom and top marks.

We have high-quality split camshaft sprockets and timing kits CLICK ON THE PICTURE

We are always ready to advise and help, contact number: 8-963-054-52-27

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Typical faults

Common breakdowns of the ZMZ 406 engine are:

• overheating of the ZMZ motor. Overheating is caused by a faulty thermostat. A clogged heat exchanger can also cause the motor to overheat, since the oil cannot circulate normally through the system and cool the working mechanisms inside the structure;
• increased consumption of ZMZ lubricant. Oil rings and valve seals are worn out. It happens that the cap of the labyrinth oil deflector leaks. You will need to dismantle it and coat it with sealant;
• dying ignition coils create dips in traction. A common problem with ZMZ engines;
• the unit is tripping. It's a matter of spark plugs and coils.

Listed above are common malfunctions of the ZMZ engine in general. Let's see what kind of breakdowns happen.

CHECKING AND ADJUSTING VALVE DISTRIBUTION PHASES OF ZMZ ENGINES

The article was prepared for publication by M. Ukhanov (aka miha, STTeam, Rostov)

During operation, as well as due to errors in the manufacture of parts for the gas distribution mechanism drive (GRM) or due to improperly carried out repairs of the timing drive, a significant deviation of the valve timing from the specified values ​​is possible. At the same time, it is known that the correct valve timing is one of the most important factors affecting the power, torque and economic performance of the engine. Therefore, when the traction properties of the engine decrease, the operating fuel consumption increases and the engine becomes unstable, it becomes necessary to check and, if necessary, correctly set the valve timing.

Checking and adjusting the valve timing can be done on an engine installed in a vehicle. To control the valve timing it is necessary:

Attention! Rotating the crankshaft counterclockwise is not permitted.

In this case, the camshaft cams of the 1st cylinder and the marks on the camshaft sprockets should be located according to the diagram:

1 – mark on the asterisk. 2 – upper plane of the cylinder head

If the tops of the cams and marks are located inward, then it is necessary to turn the crankshaft one more revolution. Precise installation of the piston of the 1st cylinder at TDC can be carried out using a dial indicator, which is installed and secured in the spark plug hole of the 1st cylinder.

A – checking the angular position of the intake camshaft. B – checking the angular position of the exhaust camshaft. 1 – cam of the intake valve of the first cylinder. 2 – cam template. 3 – protractor. 4 – cam of the exhaust valve of the first cylinder. 5 – cylinder head. 6 – hydraulic pusher.

Similarly, check the angular position of the first cam of the exhaust camshaft - view “B”.

The template arrow should point to the protractor mark 19 ° ± 2 °; when measuring, the driving branch of the chain in the area of ​​the middle damper (between the camshaft sprocket and the intermediate shaft drive sprocket) should be tensioned and held in this state by turning the exhaust camshaft counterclockwise with a wrench to “27” for the tetrahedron on the shaft body. In this case, turning the intermediate and crankshafts is not allowed. With these values ​​of the angular position of the first camshaft cams, the best technical and economic performance of the engine is achieved.

If deviations in the angular position of the camshaft cams exceed the permissible ± 2 °, adjustment of the valve timing is required.

To do this, you need to perform the following work on the engine:

Design Features

The ZMZ406 engine is a motor with four cylinders and 16 valves. The open joint stock company Zavolzhsky Motor Plant produces motors. Designed for installation in passenger vehicles and minibuses. It began to be mass produced only in 1997, although the first prototypes appeared back in 1992.

The cylinder block in the engine is made of cast iron for better rigidity and reliability. The masses of the piston and piston pin are reduced and, together with the crankshaft, are made of high-quality material. Valve mechanism hydraulic pushers are used, so there is no need to adjust the gaps.

Technical characteristics are given in the table:

Attention! The technical characteristics of ZMZ are nominal. For each modification, you must look at the instruction manual.

The ZMZ timing belt is replaced once every 100 thousand kilometers. Every 30 thousand kilometers it is necessary to monitor the condition of the timing belt. A broken chain can bend the valves. Then the repair will cost several times more than just changing the ZMZ timing belt.

Question answer

When I install this kit myself, I give a guarantee from 3 months to six months without mileage limitation, depending on the remaining condition of the engine. Of course, when it comes to our vast homeland, such guarantees would be stupid on my part. But I hope this reflects to customers the approximate reliability of the kit.

Is it possible or not to purchase part of this kit?

Maybe. For example, a client wants to re-rivet Mercedes chains, install different sprockets or tensioners. In this case, the price of the kit is calculated individually and of course there can be no guarantees on my part.

Do the components in this set change or not?

As I said above, for me personally, a similar approach from other manufacturers irritates and causes misunderstanding. Therefore, the main components of this set are unchanged. During the year of sales, compared to the initial photo, I only changed the chain tensioners. By replacing the tensioners with a wear indicator in the kits with regular ones without an indicator (from the same manufacturer). This was due to common sense logic: why do we need a wear indicator on the new “zero” double-row chains? Which may be needed after several years of operation. And the pricing of the kit is also an important thing.

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After removing the drive

After you have removed the chain and taken it out, you need to wash it. It is best to use gasoline for this. After getting rid of contaminants, you need to conduct a visual inspection. If it is stretched by more than 1-2 cm, it is better to install a new one. This increase in length is more than enough to disrupt the valve timing.

You also need to pay attention to:

1. Condition of the bushings - if there is wear, cracks or burrs, it is necessary to replace them.
2. Gears – if there are mechanical damages or chips, then they also need to be replaced.
3. Chain stabilizers - at the slightest damage, install new elements.
4. Tensioner sprockets - it is necessary that they rotate freely; chips and damage are unacceptable.

If a major overhaul of the ZMZ-406 engine is being carried out, the timing marks must be installed. This will ensure the normal operation of all systems, increase the life of the motor and its power.

Carrying out the assembly

Before you begin assembly, you need to set the phases correctly. To do this, you will need to perform the following manipulations:

1. Rotate the crankshaft until the first notch is in the upper position.
2. Make sure that the piston is at top dead center in the first cylinder.
3. Install the damper, but do not rush to tighten its mounting bolts.
4. Lubricate the bottom of the chain with clean engine oil.
5. Place the chain on the crankshaft and driven gears.
6. The crankshaft gear pin should fit into the hole in the countershaft.
7. Make sure that the mark on the gear matches the one on the motor block. The part of the chain that is located next to the damper should be tensioned.
8. Now you can tighten the bolts securing the gear to the intermediate shaft. Be sure to install the locking plates.

Be sure to use a torque wrench when making repairs. The maximum bolt tightening force is 22/2.5 N*m.

Be sure to bend the locking plate to prevent the bolts from coming out. Then you need to press the hydraulic tensioner lever and check the alignment of the marks on the engine block and the gear. After this, you need to tighten all the damper mounting bolts and lubricate the upper part of the chain drive.

Analogs

There are analogues on sale from various manufacturers - domestic and Chinese. It is possible to purchase a replacement chain separately or as a complete set. The price depends on the origin of the parts and the place of purchase. It is advisable to give preference to well-established auto shops.