Chapter 2 Part A: 2Ae1 SOHC engine procedures Contents Camshaft font oi al - removal and rofting 45 Camshat housing end camshaft ~ general ” Camefaf housing and cemeeh emorting,specion and reassembly 18 Camshaft reac sea emoval and reiting ‘6 Camsnats,“underaze” C16 NZZ, 1.8 and 20 ire engines ~ ‘general 19 Compression test- desenpion 3 Grankease venation system -descpion and mainienanes 2 Crenksha end bearings examination 35 Cranks and bearings -remova and ting 34 Graneehat Font s81-rnowal 2 Cranks er ol ea ronows 28 Gyiner black and bores - examination and renovation 36 Gyindor hood = dsmanting and roessomby 2 CGyinder heed inspection ond renovetion 2 Giindor head -rrnovl and vetting fngino avi) 20 liner heed -removal and ltng (engine removed) 2 Engine = temovel and eiting (leaving tarsmision i ca) 7 Engin ang ranemsion mountings oneal $ Engine and transmission ~remova separation, raconnaction and venting 8 Engi of and fit tonowal See Ghapior Degrees of difficulty Engine dismanting and reassembly - general 10 Exeminalion and renovation - general 7 Floxplae (aulomatic transmission) - removal and refitting 28 Fiywneal- removal, inspection and reiting 2B General description 4 Hydraule valve lifters - nspection 24 Inia star-up after major overhaul or repair Major operations possibie withthe engine inthe vehicle 4 Major operations requiring engine removal 5 Method of engine removal 6 O11 pump - aismanting, inspection and reessemibly 3 1 pump - removal and reiting 30 Pistons and connecting rods - examination and renovation 38 Pistons and connecting rods - removal and reiting 32 Sump - removal and rfiting 20 Timing belt and sprockets without automatic tensioner) - removal Tofiting and adjustment 1" Timing belt and tensioner 1.4 and 1.6 models (ot C16 NZ2) - removal, refiting and adjustment 2 Tinung bet and tensioner C16 NZ2, 1.8 and 2.0 litre - removal, reiting ‘and adjustment 14 Timing bett cover aperture, 1.4 and 1.6 mode's general 3 Easy, sutabofor Farryeasy,suiable | Fatydticut, | Dict sutaboior | Veyalticut roe te Extogmrareit SS saab torconport QS | ompernced DY S| surge for expan ry SS experiance S| somecipesence | Dvmechane SS | mechan RQ] Speen S Specifications General Type A models Founder, iin, water-cooled, transversely mounted at ont of Manufacturer's engine codes: “aNv 465V xte sz C1ENZ ci6Nz2 wesv ciBNz 20 NE 20SEH C20NE Pistons any J6SV, C18 SV, C16 NZ ang x16 SZ cieNzo ESV enc C1 NZ 20 NE, 20 SEH and C20 NE venice. Sng Belt driven overnead carsnan, acting an nyaraule valve ifters 4. tive 1389 cc) 1B Ite 1588 ce) 1.6 liso (1598 ce) ‘Ecotec’ type engine + Biive (1508 co + eatayst 1.8 ire (1598 co) catalyst “1B tre 1796 ce) 18 ve (1796 co) + catalyst 20 fre 1988 ce) 2. tne (1098 ce) + ety SRI 20 tve (1988 ce) + catalyst Bore (mm) Stroke (mm) 76 134 790 ais 800 705 a48 735 860 2602A+2. SOHC engine procedures Compression ratio TaNV 46 SV, X16 SZ, 18 SV and 20 SEH C16 Nz, C16 NZ2, C18 NZ, 20 NE and C20 NE Maximum power 14Nv 165V xIGSZ CIB NZ and C16.NZ2 1@SV and C1BNZ 20 NE and 620 NE 20SEH Maximum toraue ANY xI6SzZ yesv CIB NZ end C1BNZ2 wesv cIBNZ 20 NE 20SEH c20NE Fring order ‘Al models Cylinder block: Matoral Maximum permisibie bore out-of round Maximum permissible bore taper Maximum permissible rebore oversize Crankshaft and bearings Numer of msin bearings Main beening journal diameter (mm) “NV, 16 SV, C16 NZ and X18SZ Standard (O.25mm undersize (0.50mm undersze (G16 Nz2, 18 SV, C18 NZ, 20 NE, C20 NE and 20 SEH Standard (O.25mm undersioe 0.50mm undersize Main bearing shell colour codes: A.V, 16 SV, C16 NZ and X16 SZ ‘Stariderd (0.25 mm undorsizo (0.50 mm undoesiza (C16 NZ2, 18 SV, C18 NZ_ 20 NE, C20 NE and 20 SEH Standard (025mm undersize (050mm undersize Centre (thrust) main bearing journal with AINY, 16SV. C16 NZ and x 1657 ‘Standard (025mm undersize (50mm underse (C16 NzZ2, 18 SV, C18 NZ, 20 NE, C20NE and 20 SEH Standerd (25mm undersioe (050mm undersze Big-end bearing journal diameter (mm) ANY, 16 SV, C16 NZ and X16 52 ‘Standard (025mm undersize ‘o50mm unersze (C16 NZ2, 18 SV, C18 NZ. 20 NE, C20 NE and 20 SEH Standard (025mm undersze (050mm undersize oat 100:1 924 59 kW (75 bhp) at 9000 1pm {60 KW (82 bhp) at 5400 rpm 52 kW (71 bhp) at 5000 rpm '55 KW (75 bhp) at 5200 rpm (66 KW (90 bhp) at 5400 rpm £85 KW (116 bhp at 5200 rpm ‘95 KW (129 bnp) at 5600 pm 4108.Nm at 3000 pm 428 Nm at 2800 rpm 30 Nm at 2600 tm 425 Nm at 2800 pm +148 Nm at 2200 pm 145 Nm at 3000 rpm 4175 Nm at 2800 am 480 Nm at 4500 rpm 470 Nm at 2800 tom 41-3-4.2 (Not oyindor at timing bot ond) cast ron 0013 mm 0.013 mm 05mm ‘54.980 to 54.907 54,730 1054 747 54.482 to 54.405 57.974 to 57.905 97.792 1057 145 57-482 to 57.495 Bearing cap shells Cylinder block shells Brown Green Browne Greow/blue Brownwnite Greonvwtite Brown/grooniite Brownvblue and Green/olue Brownvwnite and Greeniwhite 26.000 to 26,052 26,200 to 26 252 26.400 to 26.452 25.850 to 26,002 26150 to 26 202 26-350 to 26.402 42.971 to 42.987 42.721 042.137 42.471 1042.487 49.070 to 48.088 48,720 to 48.738 48.470 10 48.488SOHC engine procedures 2A+3 Crankshaft and bearings (continued) Big-ond boarng shel colour codes (ll models): ‘Standard None 025 mm undersize Blue (050 mm undersio White Main and big-end besring journal out-ot-ound (all models) 0.04 mm maximum ‘Main bearing permissible movement (mm) “ANY, 16 SV, C16 NZ and X18 SZ 0.017 te 0.047 CIB NZ2, 18 SV, C18 NZ, 20 NE, C20 NE and 20 SEH 0.015 te 0.040 Big-ond boanng permissible movernent (mm) “ANY, 16 SV. C16 NZ and X16 $2 0.019te0071 C1GNZ2, 18 SV, C1B NZ, 20 NE, C20 NE and 20 SEH 0.006 ta 0.031 CGrankshatt ent rm) “ANY, 16 SV, C16 NZ and X18 S2 01to02 CIGNZ2, 18 SV, C1B NZ, 20 NE, C20 NE and 20 SEH 0.050 to 0152 Connecting red enatioat (mi) at models) oor too 24 Piston and cylinder bores (@ in mm) Bore diameter Piston ala 1D mark any: Production size 1 7758 1154 . 151 1755, 7 i158 1758 8 Production size 2 7759 757 cy 7760 17158 0 77161 17159 a1 7762 7760 a 05 mm oversizo 7807 78.05 7705 16S, CIGNZ and X16 SZ Production size 1 79.95 ra0a 5 7396 Tas 6 7397 7895 7 73.98 7896 8 Production so 2 7399 7897 9 73.00 7398 oy 7901 7399 ot 7902 7300 a Produetion sie 3 79.03 Toot 03 79.04 a0 04 79.05 moa 05, 73.08 Ta.04 6 Production size 4 79.07 70.05 a 73.08 73.08 08, 79.09 7007 9 79.10 70.08 1 (05 mm oversize 79.48 ma45 Te05 ci6Nz2 Production 7398 nia 2 73990 nis 9 80.00 nia ) 80.01 nia ot 8002 nia a 48 SV and C18 NZ: Production size 1 84.78 mm 8 Produetion sie 2 24 Tamm 29 84 80mm 84 78mm 0 84.81 mm 479mm ot 84.82 mm 840mm 2 0.5 mm oversizo 8527 mm 85.25 mm 7705 20 NE, C20 NE and 20 SEH: Production size 1 85.98 mm 25.06 men o Production size2 85,99 mm 85,97 mm 29 £860 mm 25.98 mm 0 86.01 mm 85.90rmm o 86.02 mm 86,00 a 05 mm oversize 88.47 mm 86.45 mmm 7205 Piston clearance n bore mm) ll medals) 002100042A*4 SOHC engine procedures Piston rings ‘Numbr (per piston) (all models) Rang end gap (mm) ‘Comaression Gitcontrol (top and bottom sections) Rng gap offsot to gap of adjacont rng + see Section 32 foro conto tng sections Cylinder head Material (a models) Maximum pexmissibie distartion of sealing face fall medals) Heht of eyinder head (sealing surface to Seeling surface) (all mods) Valve seat width mim) “4 NV, 16 SV, C16 NZ, X 16 SZ and C18 NZ2 ‘niet Exhaust 18 SV, C18 NZ, 20 NE, C20NE and 20 SEH ‘niet Exhaust Camshaft Camshaft bearing journal dameter: ANY, 16 SV. C16 NZ and X38 SZ No No2 No3 Nos Nos (C16 NZ2, 18 SV, C1B NZ, 20 NE, C20 NE end 20 SEH Not No2 No3 Nos Nos Camshaft bearing diameter in housing ANY, 16 SV, C16 NZ and X16 SZ: No 4 No2 No3 Nos Nos (C16 NZ2, 18 SV, C18 NZ, 20 NE, C20 NE end 20 SEH Not No2 Nos Nos Nos ‘Cam it rm: ‘4 NV (inlet and exhaust) 16 SV and C16 NZ: ‘alot Exnaust 616 NZ2, 19 SV and CB NZ Inet Exhaust (€20 NE and 20 NE inlet and exhaust) 20 SEH (mt and exhaust) ‘Maximum permissible radial run-out (om) all models) Endfoat (mm) all mode's) Timing belt (engines without automatic tension roller) Tension, using Vauxhall gauge KM-S1 0-A (see Section 11) ANV. 16 SV and CIONZ ‘New belt, cold New belt. warm Used bel, cold Used belt warm 2 compression tail contol 031005 o4to14 180" Light alloy (0025 mm 196.00 £0.25 mm yawis 161018 401015 471022 [Normal (mm) 39.435 to 30.455 39.685 to 39.705 39.935 to 39.55 40.185 to 40.205 40.495 10 40.455 42.455 to 42.470 42.705 to 42 720 42.955 to 42.970 43.205 to 43.220 43.495 10 48.470 39.500 to 39.525 539.750 to 39.775 140.000 to 40.025 40.250 to 40.275 40.500 to 40.525 42.500 to 42.525 42.750 10 42.775 43.000 to 43.025 43.250 to 43.275 43.500 10 42.525 en2 561 ei 601 639 667 6.70 04 0.030021 55 80 40 70 (041 mm undlersize 42.355 to 42.370 42.505 to 42.620 42.855 to 42 870 43.105 to 43.120 43.388 10 43.370 42.400 to 42.425 42.650 t0 42.675 42.900 to 42.025 43.150 10 43.175 43.400 10 43.425SOHC engine procedures 2A+5 48 SV, C18 NZ, 20 NE, C20 NE and 20 SEH: ‘Naw belt cold New bett, warm Used bel, cold Used bel, warm Valves and guides vera ength - production (mm): “aN AGSV, x 16 SZ and C16 NZ cieNza HSV, C1ANZ, 20 NE, C20 NE and 20 SEH Overall anath - service (mm) aN 16 SV, 16 SZ and C16 NZ cieNz2 18 SV, C18 NZ, 20 NE, C20 NE and 20 SEH Head dismeter im) ANY 46SV,X 107, ClO NZ and C16 NZD 48 SV, C18 NZ 20 NE, C20 NE and 20 SEH Stam diameter (rim), al engines} ‘Standara 0075 mm oversize 0.150 mm oversize (0.250 mm oversize Valve gue bore (mm) (all engines) ‘Standard (0075 mm oversize 0.150 mm oversize (0.250 mm oversio Vive clearance in guide imi, si engines) Inet Exhaust \Vaive seat angle ‘All models Valve claorances: ‘All models Flywheel ‘Maximum poxmssible lateral run-out of startr ring goa all models) Retnshing imit- maximum depth of material at may be removed ‘om clutch friction surface (all models) Lubrication system Lubricant typ/spoctication Lubricant eapacty 011 pump cleerances: Iimar-to-outr goarteoth clearance backiash) all models) (Gear-to-housing clearenc® enloal “4 NV, 18 SV, C16 NZ andX 18 82 CAGNZ2, 18 SV. C1B NZ. 20NE, C20 NE and 20 SEH i pressure at ide engine warm) (ll mode's) Torque wrench settings 48 75 25 70 Inet 1050 1015 4042 3082 yo18 t01.4 1038 1038 330 380 a8 6.998 t0 7.012 TTS to 7 087 7.148 to 7102 7248 to 7262 7.030 to 7.050 7.408 to 7125 7.180107 200 7.280 ta 7.300 0.018 to 0.052 0.038 to 0.072 ae Exhaust 1050 1015 1042 1040 1046 1014 1038 1036 200 310 385 6.978 106.902 053 t0 7.067 TA28t0 7.142 722810 7242 ‘Automatic adjustment by hydraulic Iitors oSmm 0.3mm eo Lubricants and fds in “Weokly checks* See Chapter 1 Spacitcations 001002 mm 0.08 t0 015mm 8.03 0.0.10 mm 1S bar (21.8 bin’) Nm wert Note: Use new bolts where astersked (). The torque settings stated for the cylinder head are only applicable fo ltest specification bots, availabe ‘om Vauxhall Easier typo or altomatve make, oad bolts may requie diferent torques. Consult your supper. ‘Ar inlet po-neat to exhaust manifold ‘Alternator and inlet marifld to brackets 14 and 1 Bite, except C10 NZ2) CAENZ2, 1.8 and 20 Ire ‘Alternator to bracket (M8) ‘Alternator to bracket (M10) ‘Aerator to shackle Big-end bearng cap: * “and 1 6 te, except G16 NZ2) Stage 1 Siago2 8 2 8 30 ao 25 25 ‘Angle tightan by 30° 6 15 3 2 20 18 82A+6 SOHC engine procedures Torque wrench settings (continued) Big-ond boanng cap: * ‘C18NZ2, +8 and 20 ive Stage 1 Stege 2 Stage 3 Camshaft nousing cover io housing Camshaft pulley to camshart Camshaft thrust pate Coolant autet to thermostat housing ‘© 18NZ2, 1.8 and 2.0 litre Coolant pump to cylinder biock 1.4and 16 lite except C 10 NZ2) (MB) (C16 NZ2, 1.8 and 20 tre (Me) Crankshaft sensor wheal (CHGNZ2, *8 and 20 ire Cynder heed to cylinder block: * "A.and 16 lite, except C16 NZ2} ‘Stage 1 Stage2 Stage 3 Stage 4 (C18 NZ2, 1.8 and 20 ive ‘Stage 1 Stage 2 Stage 3 Stage 4 Drivebelt ibbed) puleytiming belt dive to crankshaft * 1 and 16 ite, except C16 NZ2} ‘Stage 1 ‘Stage 2 Stage 9 Drivebett puley to timing bet drive Drivebet ribbed) tensioner to cylinder block Drivebet idbod) tonsioner to support 44and 16 ite, except C16 NZ2) C16 NZ2, 1.8 and 20 Ire Engine bracket to cyinder block Engine bracket to transmission Engine mounting bracket to engine Bracket Engine mounting to engine mounting bracket Engine mounting to front axe housing Engine mounting to power steoring sump suppext Engine mounting to side member Exhaust manifold to cyinder head Exhaust pipe to manifold Flexplate to crankshaft Flywhes! to crankshaft Gand 16 ite, except C10 NZ2) Stage 1 ‘Stage 2 Stage 3 C1 NZ2, 1 8and 20 tre ‘Stage 1 Stage 2 Stage 3 Front timing belt cover to rear cover Fuol pump to camshaft housing Guide sleeve release Deanng to transmission Heat shield sioaves to eyinder hoad Inlet manifold to cyinder head knock sensor to cyinder block (x16 $2) Man bearing cap." ‘Stage 1 Stage 2 Stage 3 i fitar to oi purnpeyindar block 35 ‘Angle tighten by 45° ‘Anglo tighton by 15° 8 45 8 8 8 25 a 25 ‘Angie tighten by 60° ‘Angle tighten by 60° ‘Angle tighten by 60° 25 ‘Angie tighten by 80° ‘Angle tighten by 80° ‘Angie tighten by 00° 55 ‘Angie ugnton by 45° ‘Angie tighten by 15° 20 20 20 ‘e 60 60 60 65 40 60 65 2 25 60 35 ‘Angle tighton by 30° ‘Angle ugnten by 15° 65 ‘Angle tightan by 30° ‘Angle tighten by 15° 4 8 2 20 2 3 50 ‘Angle tighten by 45° ‘Angle tighten by 15° 6 bree 26 8 8 a 5 1s 3 44 a “4 48 16 6 16 16 aSOHC engine procedures 2A+7 Oi pick-up pipe erackat to cylinder black 01 pick-up pipe to al pump 01 pipes to radiator i pressure switch to ol pump 14 and 1 Site, except C16 NZ2) C16 NZ2, 1.8 and 20 Ire (0 pressure role valve to ou pump 1 pump cover to oil pump 011 pump to cylinder block Oxygen sensor to exhaust manifold Power steonng pump brackot to suppor: ‘C16 NZ2, 1.8 and 20 Ive Power steering pump to support Right engine mounting to subframe ‘Shackle fo alternator ‘Spark plugs ‘Starter to cylinder block (M10) Startor to eylindor block (M12) ‘Sump: 14 and 1 ite, except C16 NZ2) C1GNZ2, 18 and 20 Ire ‘Sump drain plug Support to cylinder biock “Temperature sender to cylinder head “Thermostat housing: 1 and 1 6 ite, except C16 NZ2) C16 NZ2, 1.8 and 20 Ire “Timing belt tensioner to al pum 41 and 1.6 ite, excopt C18 NZ2) “Timing Delt cover to ol pumpicamsnan nousing 1 and 1 6 ite, except C16 NZ2) C16 NZ2, 1.8 and 20 Ire ‘Timing bel drive gear to crenkshatt (C16 NZ2, 1.8 and 20 ite ‘Stage 1 Stage 2 “Transmission to engine (M10) “Transmission to engine (M12) 30 40 30 30 18 5 65 25 6 60 6 55 35 20 10 6 55 130 ‘Angle tighten by betwee 45 60 2 30 2 2 3 18 4 18 3 4 "1 4a 15 6 1 40° to 50" 33 44 1. General description General ‘The engine is of four-cylinder, n-ne single ‘0r double overhead camshaft toe (depending ‘0n model), mounted transversely at tho front forthe vanice. ‘The crankshaft runs in five shell-type bearings, and the centre bearing incorporates 4 thrust Dearing shell to control crankshatt ‘endtoat. ‘The connecting rods are attached to the ‘erankshatt by norzontaly spit shell-lype big-end. bearings. On. single overhead ‘camsiraft (SOHC) models, the pistons are ailachad to the connecting rods by gudgeon pins, which are en interference ft in the connecting rod small-end bore. The ‘aluminium alloy pistons are fitted with three Piston rings: two compression rings and an oil ‘contrat ring. ‘The camshaft on SOHC engines is driven from the crankshaft by 8 toothed composite ‘ubbor belt. Each eylindr has two valves (one inlet and one exhaust), operated through rocker aims that ate supported at ther pivot fends by hydraulic self-adjusting valve afters (teppats. Tho inlet and exhaust valves are each closed by 2 single valve spring, and operat in ‘uides prossed into the cylinder hand ‘A gear-ype ol pump is located in 2 housing ‘altsched tothe front ofthe cylinder biock, and 's driven directly from the crankshatt. A fulkfow type ol fiteris ited The distributor is driven directly from the fend of the camshaft. On carburatior models, the mechanical tuel pump is operated from tha front ena of the eamshart. The coolant 'bump is located at the front of the cylinder block, ands driven by the timing belt Chapter 2A describes the SOHC engine repair procedures. Many repairs and spect cstions to the DOHC engine are similar to the 20 lire SOHC. However where they difer ‘details can be found in Chapter 28. Engine identification codes - general Before ordering spare parts, or carrying out ‘any repair or overhaul operations on the fengine, itis essential to identiy the exact ‘engine type being worked on. Later engines, slthough outwardly similar in sppearance, ‘often have significant aiferences in repair procedures, even though they may be of the ‘same displacement and model yoar “The folowing sub-Sections inthis Chapter ‘are mainly spacific to engine type, as wall be noted from the sub-Section headings. Chock the engine identineation code frst, which is tocated on a hoxzontal surface on the exhaust manifold side of the cylinder block, at the Gistibutor end. On later engines, the code is ‘on the cylinder block-to-transmission fenge, next to the engine ol dinstick 2 Crankcase ventilation x system - description and x mantenance & Description 1A crankcase ventilation system is ited to all models, but the systems differ in detall depending on the model concerned. 2 Oil fumes and blow-by gases (combustion ‘995es that have passed by the piston rings) ‘ae deawn from the crankcase into the area of