The ZMZ-406 engine is equipped with a microprocessor ignition system, which consists of a control unit for fuel injection and ignition systems, two ignition coils of types 30.3705 or 301.3705, spark plugs, high-voltage and low-voltage wires.
The control unit is installed in the car interior on the right side under the instrument panel, behind the body side upholstery.
The ignition coils are installed on the cylinder head cover.
The control unit receives signals from sensors installed on the engine and, based on this, adjusts the ignition timing, which allows for optimal power, economic and toxicity indicators.
Electrical diagram of an integrated microprocessor engine control system (KMSUD)
Ignition coil
1. Disconnect the wire from the negative terminal of the battery.
2. Disconnect 4 blocks 1 of low-voltage wires and high-voltage wires 5 from the coil.
Unscrew bolts 2, remove bar 3 and coil 4.
3. Remove the second coil in the same way.
Examination
1. Coils 30.3705 and 301.3705 are checked with a spark plug diagnostician 1AP975000 on a car.
To do this, disconnect the high-voltage wires from the coil and connect the diagnostician instead.
Then crank the engine with the starter, while a spark should jump in the diagnostic spark gap in time with the operation of the cylinders.
2. Check the resistance of the primary winding of the ignition coil by connecting an ohmmeter between the low voltage terminals.
The ohmmeter should show a resistance of 0.025–0.03 ohms.
Then check the resistance of the secondary winding by connecting an ohmmeter between the high voltage terminals of the ignition coil.
The ohmmeter should show a resistance of 4000–5000 ohms.
If the measured parameters differ from those specified, the coil must be replaced.
Install the ignition coil in the reverse order of removal.
Connecting high-voltage wires ZMZ 405, ZMZ 406
ZMZ carburetor and Euro-2 engines are equipped with a DIS (Double Ignition System) ignition system.
The DIS system uses ignition coils with two high-voltage wires. Each coil operates a corresponding pair of cylinders.
The first coil works with 1 and 4 cylinders, the second coil works with 2 and 3 cylinders.
How to connect the ignition coils?
The ignition coil of cylinders 1 and 4 is located closer to the intake manifold, the coil of cylinders 2 and 3 is closer to the exhaust manifold.
Low-voltage coil wires must be connected to the coil in pairs. The pair of wires for coil 1-4 is slightly shorter than the pair of wires for coil 2-3.
Within the pair, it does not matter which contact is connected to which wire - the coils are non-polar. Also, within the pair, it does not matter which high-voltage wire goes to which cylinder.
Let's look at an example (see photo)
Coil 1 control (cylinders 1 and 4) – green and yellow wires. This pair connects strictly to the coil of cylinders 1 and 4!
Low voltage circuit - polarity is not important - can be connected:
Option 1: The top coil contact is yellow, the bottom contact is green.
Option 2: The top coil contact is green, the bottom contact is yellow.
High voltage outputs – polarity is not important – can be connected:
Option 1: Top outlet for cylinder 1, bottom outlet for cylinder 4.
Option 2: Top outlet for cylinder 4, bottom outlet for cylinder 1.
Coil 2 control (cylinders 2 and 3) – blue and yellow wires. This pair is connected strictly to the coil of cylinders 2 and 3! Further - similar to pair 1-4 - the polarity within the pair is not important.
The determining factor when connecting pairs of low-voltage and high-voltage wires to the corresponding ignition coil is the correctness of their routing. The wires should not be too tight, bent too much, and should not rub against fixed parts of the engine or other wires.
Another article about high-voltage wires ZMZ 405, 406 - read so as not to repeat this mistake.
What are the requirements for spark plug wires?
Any conductor has a certain service life. If the cables are laid in a bundle, have an outer braid and are fixed permanently (protected from vibration loads), the service life is equal to the life expectancy of the car. Another thing is the high-voltage ignition coil wire. It is located in the epicenter of unfavorable conditions: vibration, high temperature (as well as changes in winter), gasoline vapors, therefore high demands are placed on the quality of insulation of high-voltage wires and the core:
- The conductors are exclusively copper (as is known, this material has the lowest resistance), but the protective layer can be silicone or rubber. Other insulation materials, although they have good protection, are not soft enough. Another requirement for high-voltage wires is elasticity. Otherwise, the surface will simply crack due to constant vibration;
- Shell thickness is a compromise. If a breakdown of high-voltage wires occurs, a spark will form between the central core and the motor housing. The voltage will not reach the spark plug, but the presence of a sparking conductor in the engine compartment, to put it mildly, is not useful for the car. The other side of the coin is that a wire that is too thick is inconvenient to install, it is inelastic, which makes installation and maintenance difficult;
- The length of high-voltage wires is another headache for the manufacturer. From Ohm's law it is known: the shorter the conductor, the less losses for electric current. In a car, it is not so easy to place all the interacting components next to each other. Mounting the ignition coil above the spark plug wells is good for electricians, but bad for builders. In addition, it is desirable that the cables be of similar length, so the connection diagram for high-voltage wires is carefully calculated, and replacing the cables with universal ones means disrupting the operation of the entire ignition system on the car.
Parameters of the main components of the ZMZ-406 engine
The engine is gasoline, four-cylinder, in-line with an integrated microprocessor control system for fuel injection and ignition.
The ZMZ-406 engine is installed on GAZ-3110 Volga passenger cars and GAZ-3302 Gazelle trucks.
The main design features of the ZMZ-406 engine of the GAZ-3110 Volga, Gazelle GAZ-3302 cars are the upper (in the cylinder head) arrangement of two camshafts with the installation of four valves per cylinder (two inlet and two exhaust).
Increasing the compression ratio to 9.3 (instead of 8.2 on the 402 model engine) due to a combustion chamber with a central spark plug, using a system of distributed (alternately in accordance with the order of operation of the cylinders) fuel injection into the intake pipe using electromagnetic injectors (instead of carburetor supply) .
This made it possible to significantly increase maximum power (about 1.5 times) and maximum torque, reduce fuel consumption and reduce exhaust gas toxicity.
To increase the reliability of the ZMZ-406 engine of the GAZ-3110 Volga, GAZ-3302 Gazelle cars under operating conditions using more power and higher crankshaft speeds, a cast-iron cylinder block without insert liners is used on the engine, which has high rigidity and more stable gaps in friction pairs , the piston stroke was reduced from 92 mm to 86 mm, the weight of the piston and piston pin was reduced, higher quality materials were used for the crankshaft, connecting rods, connecting rod bolts, piston pins, etc.
The engine camshaft drive is a two-stage chain drive with automatic hydraulic chain tensioners; The valve mechanism uses hydraulic pushers, eliminating the need to adjust the gaps.
The use of hydraulic devices and the high degree of boost of the ZMZ-406 engine require a higher quality of oil purification, therefore the engine uses a full-flow oil filter with an additional filter element, which prevents the entry of unclean oil into the engine when starting a cold engine and clogging the main filter element.
The drive of auxiliary units (water pump and generator) is carried out by a more reliable flat poly-V-belt.
The ZMZ-406 engine is equipped with a diaphragm clutch with so-called ellipsoid-wound driven disk linings, which have high durability.
The integrated control system also includes functions for controlling the ignition system and allows you to more accurately dose the fuel supply and adjust the ignition timing, including the detonation parameter, under changing engine operating conditions, which allows you to ensure the necessary power, economic and toxic indicators.
What is needed for remodeling
If you modernize it, it will be completely, including the injector, and for this you should take a closer look at the Digitronic gas-cylinder equipment. This HBO is praised by many, and it can be installed on Gazelle.
Many people know about the economical consumption of a car with LPG.
But there is one significant nuance - to equip a car with Digitronic, you need an injection engine, “tuned” to Euro-2 toxicity standards.
And then, modifications for the injector will not end there, because the following components and parts will be needed:
- Injector wiring on the Gazelle - 406 engine does not have it, not to mention the control unit;
- Intake system, including the manifold itself with the injector ramp, throttle position sensor, throttle pipe, idle air control and additional air regulator, connecting pipes and pipes;
Engine Description
Previously, the engine was designed for newfangled power and ignition systems, which were controlled by a microprocessor.
This engine was the first to be equipped with four valves per cylinder, with hydraulic lifters and two camshafts with a double chain drive. An electronic fuel supply system and electronic ignition were also installed.
The four cylinders have an in-line arrangement, a water jacket and controlled fuel injection.
The ZMZ-406 injector runs on A-92 gasoline. Previously, a carburetor version of the 4061 engine was produced, which ran on seventy-sixth gasoline. It had limitations in terms of release.
The unit is unpretentious in maintenance. It has a high degree of reliability. Later, on its basis, ZMZ-405 and 409 units were developed, as well as a diesel version of the engine labeled ZMZ-514.
The disadvantages of the engine include the cumbersome nature of the gas distribution mechanism drive, which is explained by its low quality of workmanship and a number of technological shortcomings.
Checking the spark plugs yourself
According to the wiring diagram for engines 405, 406 and 409, spark plugs are used to transfer spark from the switchgear to the engine cylinders. If the operation of the SZ is disrupted, this may affect the quality of the motor as a whole.
To check devices you will need an assistant:
- You need to disconnect the high-voltage wire from the first SZ.
- Using a key, the product is unscrewed from its seat.
- One end of the device from the electrode side should be brought to the engine or metal on the car body, the distance between the electrode and the ground should be about 1-2 mm.
- The assistant then turns the starter to try to start the engine. If at the moment of cranking a spark jumps between the electrode and the body, this indicates that the product is operational. In the same way, you need to check each SZ. Please note that problems with spark supply can also be caused by improper operation of the distributor, as well as damage to high-voltage wires.
Carburetor engine
The ZMZ-406 carburetor (402nd engine) has been produced since 1996 and has managed to establish itself as a simple and reliable unit. This device develops a power of 110 horsepower. The fuel consumption of a car with this engine often depends on driving style and operating conditions. The power system of the carburetor unit is quite reliable. With timely maintenance and normal operation, using high-quality lubricants and gasoline, it can travel up to 500 thousand kilometers without serious breakdowns. Of course, with the exception of boring the crankshaft, which is necessary for this unit once every 250 thousand kilometers.
FakeHeader
Comments 15
I read it, even the first time))
And my engine dangles back and forth at idle. CHANGED SPARKLES WIRES COILS MARKS SENSORS ALL
