Carefully wash and prepare the engine for disassembly

We install the engine on a stand or stand. We prepare the necessary tool for disassembly.

When disassembling, you need to mark the parts that will be used in the future.

The crankshaft, flywheel and clutch are balanced as an assembly, so they cannot be dismantled.

With a 10 head, we unscrew the six bolts securing the cylinder block cover and remove the cover along with the gasket.

Remove dipstick

Disassembly of the ZMZ-402 engineРазборка двигателя ЗМЗ-402

Using a 12 key, we loosen the bolt of the upper fastening of the generator

Using a 13 key, unscrew the nut that secures the adjusting plate to the head of the block

Disassembly of the ZMZ-402 engineDisassembly of the ZMZ-402 engine

Remove the plate from the head stud

We turn off with a 13 key the two nuts securing the extreme racks of the rocker arm axis

Disassembly of the ZMZ-402 engineDisassembling the ZMZ-402 engine

Using a 17 key, we evenly loosen and unscrew the four nuts securing the main racks of the rocker axis

Remove the rocker axle from the studs

Disassembling the ZMZ-402 engine

We take out eight push rods and lay them out in order, so that later we can put them in their places

Remove the tips of high-voltage wires and turn out the spark plugs.

Disconnect the hose from the fine fuel filter.

Disconnect the vacuum corrector hose of the ignition distributor sensor from the carburetor.

Disassembling the ZMZ-402 engine

With a 19 head, we unscrew ten nuts securing the head of the block in the reverse tightening sequence

ZMZ-402 engine disassembly

Cylinder head bolt tightening sequence

Disassembling the ZMZ-402 engineРазборка двигателя ЗМЗ-402

Remove the head from the cylinder block studs.

Remove the cylinder head gasket

ZMZ-402 engine disassembly

Turn the engine over with the pallet up and with a 13 key, unscrew the eighteen nuts securing the pallet.

Curly washers are installed under the corner nuts of the pallet fastening

Disassembling the ZMZ-402 engineDisassembling the ZMZ-402 engine

Remove the front and back of the gasket from the pallet

Remove the side parts of the gasket from the block

Seals cannot be reused. All gaskets are sold in repair kits.

Disassembly of the ZMZ-402 engineDisassembling the ZMZ-402 engine

Using a 12-head with an extension, unscrew the two fuel pump mounting bolts

Remove the fuel pump

ZMZ-402 engine disassembly Disassembling the ZMZ-402 engine

Between pump and block installed gasket

Use a 24 key to unscrew the bolt and disconnect the tube from the oil filter housing

Disassembling the ZMZ-402 engineDisassembling the ZMZ-402 engine

Using a 13 key, we unscrew the four nuts securing the oil filter

Remove the oil filter

Disassembly of the ZMZ-402 engineDisassembling the ZMZ-402 engine

With a 14 key, we unscrew six nuts and two bolts securing the clutch housing

Remove the clutch housing

Disassembly of the ZMZ-402 engineDisassembly of the ZMZ-402 engine

With a 24 key, turn off and remove the oil cooler tap and oil pipe

Use a 12 key to unscrew the fitting and remove the oil level indicator tube

Remove the timing gear cover for this:

ZMZ-402 engine disassembly Disassembling the ZMZ-402 engine

Use a 46 socket wrench to turn off the ratchet

With a 12 head, we unscrew the six bolts securing the pulley

Disassembly of the ZMZ-402 engineРазборка двигателя ЗМЗ-402

Remove the crankshaft pulley

Using a three-fingered puller, we tighten the pulley hub

Disassembly of the ZMZ-402 engineРазборка двигателя ЗМЗ-402

Using a 13 key, we unscrew the eight nuts securing the front cover

Remove the timing gear cover

Disassembly of the ZMZ-402 engineDisassembly of the ZMZ-402 engine

Using a 13 key, we unscrew the two nuts securing the cover of the pusher box.

Remove the cover of the pushers

Disassembling the ZMZ-402 engineDisassembling the ZMZ-402 engine

We take out eight valve lifters and mark them or put them in order

Using a beard we knock out the key

Disassembly of the ZMZ-402 engine Disassembly of the ZMZ-402 engine

Remove the oil deflector from the crankshaft

With a head of 12, through the hole in the gear, unscrew the bolts of the thrust flange

Disassembling the ZMZ-402 engineDisassembling the ZMZ-402 engine

We take out the camshaft together with the gear

We fix the sleeves from falling out with the help of suitable bushings, washers and nuts

If the cylinder liners are not fixed, then when the crankshaft is turned, they can rise due to friction against their piston mirrors.

Scale particles from the water jacket will get under the landing shoulders of the liners, and when assembling the engine, the liners will not sit tightly in their places, which will lead to leakage of coolant into the oil sump.

Turning the blok cylinders.

Disassembling the ZMZ-402 engineDisassembling the ZMZ-402 engine

With a 13 head, we unscrew the two nuts securing the oil pump

Remove the oil pump

Disassembly of the ZMZ-402 engineDisassembling the ZMZ-402 engine

Using an 8 hexagon, unscrew the two nuts securing the stuffing box holder

Remove the rear bearing oil seal holder

Disassembly of the ZMZ-402 engineDisassembly of the ZMZ-402 engine

With a head of 15, we unscrew the two nuts of the connecting rod cover

Remove the connecting rod cover

Disassembling the ZMZ-402 engine

Squeeze the piston out of the cylinder with the wooden handle of the hammer.

We also take out the rest of the pistons.

Disassembly of the ZMZ-402 engineРазборка двигателя ЗМЗ-402

Head 19. unscrew the two nuts securing the main bearing cap

Remove the main bearing cap.

We also remove the remaining main bearing caps.

Disassembling the ZMZ-402 engineDisassembling the ZMZ-402 engine

Remove the crankshaft from the block

Unscrew the device holding the shells and take them out.

Marking the sleeves

After that, we wash all the parts and prepare them for fault detection

Select your language