Removing the camshaft

Remove the cylinder head cover

The fuel rail is removed to replace injectors and repair the cylinder head, as well as when replacing the rail itself

Checking the thermostat

After starting a cold engine, the main thermostat valve is closed, and the upper part of the thermostat housing in good condition remains colder than other parts of it for some time

Pressure reduction in the supply system

Remove the No. 9 fuse (fuel pump fuse) from the right fuse box.

Drain the oil from the crankcase.

Remove the oil pan.

At the engine mod. 406 the oil pump is driven by an intermediate shaft, for engine mod. 402 the pump and ignition distributor are driven by the camshaft

On engines mod. 406, filter 2101-1012005 is used, installed at the bottom of the cylinder block on the right side.

In order to replace the filter, you need to unscrew the old filter and screw in the new one.

Put a waste oil container under the crankcase

Unscrew the plug and drain the oil from the crankcase

Compression (pressure at the end of the compression stroke) in the cylinders is the most important indicator for diagnosing the condition of the engine without disassembling it

You will need: a hex wrench “6”, heads “12”, “13”, “14”, a small chisel, a hammer

Drain the engine oil and coolant, remove the mudguard and accessory drive belt

The piston of the 1st cylinder is set to the position of the top dead center (TDC) of the compression stroke so that when carrying out work related to the removal of the timing chains, the installation of the gas distribution phases is not disturbed

Removal, repair and installation of camshafts ZMZ-405, ZMZ-406

Remove the tips of the spark plugs together with high-voltage wires, ignition coils (you can only disconnect the connectors, leaving them on the valve cover),

If the gasket is leaking, the exhaust gases break out, accompanied by a characteristic sound (“cut” collector)

Replacing the oil sump seal ZMZ-406

If an oil leak through the oil pan gasket cannot be eliminated by tightening its fastening bolts, it means that the gasket is severely deformed and must be replaced

Replacing the front crankshaft seal

A sign of the need to replace the front crankshaft oil seal is an oil leak through its edge

Replacing the cylinder head gasket ZMZ-406

The cylinder head gasket is replaced if it is damaged

Replacing the cylinder head cover gasket ZMZ-406

Over time, during operation, the gasket under the engine head cover loses its elasticity and strength and oil leaks from under the cover

Removal, inspection and installation of the ZMZ-406 flywheel

The flywheel is removed to replace the rear crankshaft oil seal, to replace it if the toothed rim used to start the engine with the starter is damaged, and to grind the surface under the clutch driven disc