Vauxhall Workshop Service and Repair Manuals

 

Crank Drive, Cylinder Block   (X 16 XEL, Y 16 XE, Z 16 XE, X 18 XE1, Z 18 XE, Z 18 XEL)   Illustration     1  Main Bearing Journals   2  Con-rod bearing journal   3  3 Main Bearing Journals (Guide Bearing)   4  Crankshaft colour code   5  Bearing shell colour code   6  Bearing shell identification

Crank Drive, Cylinder Block (Continued)  

Engine			X 16 XEL, Y 16 XE, Z 16 XE, X 18 XE1, Z 18 XE, Z 18 XEL
Crankshaft dimensions			Ø Main Bearing Journals	Colour code
			1 - 5
	Standard size	mm	54.980 - 54.997	brown
		mm	54.980 - 54.997	green
	Undersize (0.25)	mm	54.730 - 54.747	brown / blue
		mm	54.730 - 54.747	green / blue
	Undersize (0.50)	mm	54.482 - 54.495	brown / white
		mm	54.482 - 54.495	green / white
			Ø Con-rod bearing journal
			1 - 4
	Standard size	mm	42.971 - 42.987	-
	Undersize (0.25)	mm	42.721 - 42.737	blue
	Undersize (0.50)	mm	42.471 - 42.487	white
			3 wide main bearing journals (guide bearing)
	Standard size	mm	26.000 - 26.052	-
	Undersize (0.20)	mm	26.200 - 26.252	-
	Undersize (0.40)	mm	26.400 - 26.452	-

Crank Drive, Cylinder Block (Continued)  

Engine			X 16 XEL, Y 16 XE, Z 16 XE, X 18 XE1, Z 18 XE, Z 18 XEL
Crankshaft bearing			Lower crankshaft bearing shell
1, 2, 4, 5			Colour code	Thickness	Code
					GM 15, 74, 985
	Standard size	mm	brown	1.987 - 1.993	256 N
		mm	green	1.993 - 1.999	257 N
	Undersize (0.25)	mm	brown / blue	2.112 - 2.118	258 A
		mm	green / blue	2.118 - 2.124	259 A
	Undersize (0.50)	mm	brown / white	2.237 - 2.243	260 B
		mm	green / white	2.243 - 2.249	261 B
			Upper crankshaft bearing shell
	Standard size	mm	brown	1.987 - 1.993	256 N
		mm	green	1.993 - 1.999	257 N
	Undersize (0.25)	mm	brown / blue	2.112 - 2.118	258 A
		mm	green / blue	2.118 - 2.124	259 A
	Undersize (0.50)	mm	brown / white	2.237 -2.243	260 B
		mm	green / white	2.243 - 2.249	261 B

Crank Drive, Cylinder Block (Continued)  

Engine			X 16 XEL, Y 16 XE, Z 16 XE, X 18 XE1, Z 18 XE, Z 18 XEL
Crankshaft
	Perm. crankshaft bearing clearance	mm	0.013 - 0.043
	Perm. crankshaft end clearance	mm	0.100 - 0.202
	Permissible crankshaft out-of-round	mm	0.03

Crank Drive, Cylinder Block (Continued)  

Engine			X 16 XEL, Y 16 XE, Z 16 XE, X 18 XE1, Z 18 XE, Z 18 XEL
Crankshaft bearing 3			Lower crankshaft bearing shell
(guide bearing)			Colour code	Thickness	Code
					GM 15, 74, 985
	Standard size	mm	brown	1.987 - 1.993	859 N
		mm	green	1.993 - 1.999	860 N
	Undersize (0.25)	mm	brown / blue	2.112 - 2.118	861 A
		mm	green / blue	2.118 - 2.124	862 A
	Undersize (0.50)	mm	brown / white	2.237 - 2.243	863 B
		mm	green / white	2.243 - 2.249	864 B
			Upper crankshaft bearing shell
	Standard size	mm	brown	1.987 - 1.993	859 N
		mm	green	1.993 - 1.999	860 N
	Undersize (0.25)	mm	brown / blue	2.112 - 2.118	861 A
		mm	green / blue	2.118 - 2.124	862 A
	Undersize (0.50)	mm	brown / white	2.237 -2.243	863 B
		mm	green / white	2.243 - 2.249	864 B

Crank Drive, Cylinder Block (Continued)  

Engine			X 16 XEL, Y 16 XE, Z 16 XE, X 18 XE1, Z 18 XE, Z 18 XEL
3 wide main bearing journals (guide bearing)			Colour code	Thickness	Code
	Standard size	mm	green - brown	25.850 - 25.900	-
	Undersize (0.25)	mm	brown / blue	26.050 - 26.100	-
		mm	green / blue
	Undersize (0.50)	mm	brown / white	26.250 - 26.300	-
		mm	green / white

Crank Drive, Cylinder Block (Continued)  

Engine			X 16 XEL, Y 16 XE, Z 16 XE, X 18 XE1, Z 18 XE, Z 18 XEL
Con-rod bearing			Lower con-rod bearing shell
			Colour code	Thickness	Code
					GM 985.3
	Standard size	mm	-	1.485 - 1.497	264 N
	Undersize (0.25)	mm	blue	1.610 - 1.622	265 A
	Undersize (0.50)	mm	white	1.735 - 1.747	266 B
			Upper con-rod bearing shell
	Standard size	mm	-	1.485 - 1.497	264 N
	Undersize (0.25)	mm	blue	1.610 - 1.622	265 A
	Undersize (0.50)	mm	white	1.735 - 1.747	266 B
Perm. con-rod play		mm	0.019 - 0.071

Crank Drive, Cylinder Block (Continued)  

Illustration  

 

1  Index - identification of cylinder bore   2  Cylinder bore   3  Double bevelled ring with spiral-type expander   4  Tapered compression ring or double trapezoidal ring   5  Rectangular compression ring   6  Piston diameter

Crank Drive, Cylinder Block (Continued)  

Engine				X 16 XEL, Y 16 XE, Z 16 XE	X 18 XE1, Z 18 XE, Z 18 XEL
Ø Cylinder bore
	Standard size
		Index 5	mm	-	-
		Index 6	mm	-	-
		Index 7	mm	-	-
		Coefficient 8	mm	78.975 - 78.985	-
		Coefficient 99	mm	78.985 - 79.995	80.485 - 80.495
		Coefficient 00	mm	78.995 - 79.005	80.495 - 80.505
		Coefficient 01	mm	79.005 - 79.015	80.505 - 80.515
		Coefficient 02	mm	79.015 - 79.025	-
		Index 03	mm	-	-
		Index 04	mm	-	-
		Index 05	mm	-	80.545 - 80.555
		Index 06	mm	-	-
		Index 07	mm	-	-
		Index 08	mm	-	-
		Index 09	mm	-	-
		Index 1	mm	-	-
	Oversize 1)
		Index 7 + 0.5	mm	79.465 - 79.475	80.995 - 81.005

1)  After re-boring the old index must be invalidated and the new oversizing index must be embossed.  

Crank Drive, Cylinder Block (Continued)  

Engine				X 16 XEL, Y 16 XE, Z 16 XE	X 18 XE1, Z 18 XE, Z 18 XEL
Ø Piston
	Standard size
		Index 5	mm	-	-
		Index 6	mm	-	-
		Index 7	mm	-	-
		Coefficient 8	mm	78.955 - 78.965	-
		Coefficient 99	mm	78.965 - 78.975	80.455 - 80.465
		Coefficient 00	mm	78.975 - 78.985	80.465 - 80.475
		Coefficient 01	mm	78.985 - 78.995	80.475 - 80.485
		Coefficient 02	mm	78.995 - 79.005	-
		Index 03	mm	-	-
		Index 04	mm	-	-
		Index 05	mm	-	80.515 - 80.525
		Index 06	mm	-	-
		Index 07	mm	-	-
		Index 08	mm	-	-
		Index 09	mm	-	-
		Index 1	mm	-	-
	Oversize 1)
		Index 7 + 0.5	mm	79.445 - 79.455	80.965 - 80.975

1)  After re-boring the old index must be invalidated and the new oversizing index must be embossed.  

Crank Drive, Cylinder Block (Continued)  

Engine				X 16 XEL, Y 16 XE, Z 16 XE	X 18 XE1, Z 18 XE, Z 18 XEL
Piston rings
	Rectangular compression ring
		Height	mm	1.20	1.175 - 1.19
		Gap	mm	0.30 - 0.50	0.20 - 0.40
		Vertical play	mm	0.02 - 0.04	-
	Tapered compression ring
		Height	mm	1.50	1.175 - 1.19
		Gap	mm	0.30 - 0.50	0.40 - 0.60
		Vertical play	mm	0.04 - 0.06	-
	Oil scraper ring
		Height	mm	2.50	1.88 - 1.96
		Gap	mm	0.40 - 1.40	0.25 - 0.75
		Vertical play	mm	0.01 - 0.03	-
Ring gap distribution 1)			°	180	180

1)  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.  

Crank Drive, Cylinder Block (Continued)  

Engine				X 16 XE, Y 16 XE, Z 16 XE	X 18 XE1, Z 18 XE, Z 18 XEL
Piston pin
	Length		mm	55	55
	Diameter		mm	17.997 - 18.000	17.997 - 18.000
	Bearing			shrunk in con-rod
	Clearance
		in piston	mm	0.09 - 0.012	0.009 - 0.015
		in con-rod	mm	0	0