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Crank drive, cylinder block - DOHC II
Illustration
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1
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Main Bearing Journals
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2
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Con-rod bearing journal
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3
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3 Main Bearing Journals (Guide Bearing)
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4
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Crankshaft colour code
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5
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Bearing shell colour code
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6
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Bearing shell identification
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Engine
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X 20 XEV, Y 22 XE, Z 22 XE
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Crankshaft dimensions
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Ø Main bearing journals 1 - 5
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Colour coding
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Standard size
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mm
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57.974 - 57.981
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white
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mm
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57.981 - 57.988
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green
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mm
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57.988 - 57.995
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brown
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Undersize (0.25)
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mm
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57.732 - 57.738
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green / blue
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mm
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57.738 - 57.745
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brown / blue
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Undersize (0.50)
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mm
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57.482 - 57.488
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green / white
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mm
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57.488 - 57.495
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brown / white
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Ø Con-rod bearing journals 1 - 4
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Standard size
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mm
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48.970 - 48.988
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-
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Undersize (0.25)
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mm
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48.720 - 48.738
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blue
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Undersize (0.50)
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mm
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48.470 - 48.488
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white
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Width of main bearing
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journal 3
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(Guide bearing)
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Standard size
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mm
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25.950 - 26.002
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-
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Undersize (0.20)
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mm
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26.150 - 26.202
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-
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Undersize (0.40)
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mm
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26.350 - 26.402
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-
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Engine
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X 20 XEV, Y 22 XE, Z 22 XE
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Crankshaft bearing
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lower crankshaft bearing shell
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1, 2, 4, 5
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Colour coding
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Thickness
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Coding
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GM 985
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Standard size
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mm
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brown
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1.989 - 1.995
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662 N
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mm
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green
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1.995 - 2.001
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663 N
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mm
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white
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2.001 - 2.007
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528 N
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Undersize (0.25)
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mm
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brown / blue
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2.114 - 2.120
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664 A
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mm
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green / blue
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2.120 - 2.126
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665 A
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Undersize (0.50)
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mm
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brown / white
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2.239 - 2.245
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666 B
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mm
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green / white
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2.245 - 2.251
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667 B
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upper crankshaft bearing shell
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Standard size
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mm
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brown
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1.989 - 1.995
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662 N
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mm
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green
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1.995 - 2.001
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663 N
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mm
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white
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2.001 - 2.007
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528 N
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Undersize (0.25)
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mm
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brown / blue
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2.114 - 2.120
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664 A
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mm
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green / blue
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2.120 - 2.126
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665 A
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Undersize (0.50)
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mm
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brown / white
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2.239 - 2.245
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666 B
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mm
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green / white
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2.245 - 2.251
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667 B
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Permitted crankshaft bearing play
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mm
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0.015 - 0.043
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Permitted crankshaft end play
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mm
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0.050 - 0.152
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Permitted out-of-round
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mm
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0.03
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Engine
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X 20 XEV, Y 22 XE, Z 22 XE
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Crankshaft bearing 3
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lower crankshaft bearing shell
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(Guide bearing)
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Colour coding
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Thickness
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Coding
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GM 985
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Standard size
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mm
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brown
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1.989 - 1.995
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655 N
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mm
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green
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1.995 - 2.001
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656 N
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mm
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white
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2.001 - 2.007
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126 N
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Undersize (0.25)
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mm
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brown / blue
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2.114 - 2.120
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657 A
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mm
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green / blue
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2.120 - 2.126
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658 A
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Undersize (0.50)
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mm
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brown / white
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2.239 - 2.245
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659 B
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mm
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green / white
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2.245 - 2.251
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660 B
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upper crankshaft bearing shell
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Standard size
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mm
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brown
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1.989 - 1.995
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655 N
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mm
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green
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1.995 - 2.001
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656 N
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mm
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white
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2.001 - 2.007
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126 N
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Undersize (0.25)
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mm
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brown / blue
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2.114 - 2.120
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657 A
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mm
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green / blue
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2.120 - 2.126
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658 A
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Undersize (0.50)
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mm
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brown / white
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2.239 - 2.245
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659 B
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mm
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green / white
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2.245 - 2.251
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660 B
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Engine
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X 20 XEV, Y 22 XE, Z 22 XE
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Wide crankshaft bearing 3
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Colour coding
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Width
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Coding
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(Guide bearing)
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Standard size
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mm
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brown - green
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25.850 - 25.900
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-
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- white
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Undersize (0.25)
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mm
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brown / blue
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26.050 - 26.100
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-
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green / blue
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Undersize (0.50)
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mm
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brown / white
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26.250 - 26.300
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-
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green / white
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Engine
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X 20 XEV, Y 22 XE, Z 22 XE
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Con-rod bearing
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lower con-rod bearing shell
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Colour coding
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Thickness
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Coding
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GM 124
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Standard size
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mm
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-
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1.490 - 1.500
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623 N
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Undersize (0.25)
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mm
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blue
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1.615 - 1.625
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624 A
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Undersize (0.50)
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mm
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white
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1.740 - 1.750
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625 B
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upper con-rod bearing shell
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Standard size
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mm
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-
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1.490 - 1.500
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623 N
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Undersize (0.25)
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mm
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blue
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1.615 - 1.625
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624 A
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Undersize (0.50)
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mm
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white
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1.740 - 1.750
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625 B
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Permitted con-rod bearing play
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mm
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0.006 - 0.031
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Illustration
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1
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Index-identification of cylinder bore
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2
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Cylinder bore
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3
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Double bevelled ring with spiral-type expander
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4
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Tapered compression ring or double trapezoidal ring
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5
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Rectangular compression ring
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6
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Piston diameter
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Engine
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X 20 XEV
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Ø cylinder bore
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Standard size
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Coefficient 99
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mm
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85.985 - 85.995
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Coefficient 00
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mm
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85.995 - 86.005
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Coefficient 01
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mm
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86.005 - 86.015
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Index 05
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mm
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86.045 - 86.055
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Oversize
1)
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Index 0 + 0.5
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mm
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86.495 - 86.505
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Ø Piston
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Standard size
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Coefficient 99
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mm
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85.967 - 85.983
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Coefficient 00
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mm
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85.977 - 85.993
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Coefficient 01
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mm
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85.987 - 86.003
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Index 05
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mm
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86.027 - 86.043
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Oversize
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Index 0 + 0.5
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mm
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86.477 - 86.493
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Piston clearance
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mm
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0.002 - 0.028
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Piston projection
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mm
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0.4
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Engine
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Y 22 XE, Z 22 XE
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Ø cylinder bore
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Standard size
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Coefficient 8
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mm
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85.975 - 85.985
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Coefficient 99
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mm
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85.985 - 85.995
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Coefficient 00
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mm
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85.995 - 86.005
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Coefficient 01
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mm
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86.005 - 86.015
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Coefficient 02
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mm
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86.015 -86.025
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Oversize
1)
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Index 7 + 0.5
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mm
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86.465 - 86.475
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Ø Piston
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Standard size
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Coefficient 8
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mm
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85.955 - 85.965
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Coefficient 99
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mm
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85.965 - 85.975
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Coefficient 00
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mm
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85.975 - 85.985
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Coefficient 01
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mm
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85.985 - 85.995
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Coefficient 02
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mm
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85.995 - 86.005
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Oversize
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Index 7 + 0.5
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mm
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86.445 - 86.455
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Piston clearance
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mm
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0.01 - 0.03
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Piston projection
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mm
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0.4
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Engine
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X 20 XEV
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Y 22 XE, Z 22 XE
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Piston rings
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Rectangular compression ring
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Height
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mm
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1.50
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1.20
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Gap
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mm
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0.30 - 0.50
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Vertical play
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mm
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0.02 - 0.04
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0.03 - 0.05
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Tapered compression ring
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Height
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mm
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1.50
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Gap
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mm
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0.30 - 0.50
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Vertical play
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mm
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0.02 - 0.04
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Oil scraper ring
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Height
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mm
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3.00
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2.50
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Gap
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mm
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0.40 - 1.40
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Vertical play
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mm
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0.01 - 0.03
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Ring gap distribution
2)
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°
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120
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Engine
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X 20 XEV
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Y 22 XE, Z 22 SE
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Piston pin
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Length
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mm
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61.20 - 61.50
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Diameter
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mm
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20.99 - 21.00
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Bearing
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shrunk in con-rod
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Clearance
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in piston
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mm
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0.007 - 0.022
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0.009 - 0.024
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in con-rod
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mm
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0
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1 ) After re-boring, the old index must be
invalidated and the new oversizing index must be embossed.
2 ) Arrange gap of upper oil scraper ring 25 to 50
mm offset to the left and gap of the lower ring 25 to 50 mm offset
to the right relative to the gap of the lower intermediate ring.
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