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Wiring diagrams Section: DOHC Petrol Engine

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Crank Drive, Cylinder Block Opel Corsa D

DOHC Petrol Engine 3 illustrations

Illustration

Crank Drive, Cylinder Block

1. Main bearing journal
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

Illustration

Z 16 LER / Z16 LEL
1	Production date of cylinder block
2	Index code for cylinder bore of cylinder 1
3	Index code for cylinder bore of cylinder 2
4	Index code for cylinder bore of cylinder 3
5	Index code for cylinder bore of cylinder 4
6	Index-identification of crankshaft bearing shell mount in cylinder block

Crank Drive, Cylinder Block

Engine			Z 16 LER / Z16 LEL
Crankshaft dimensions			Ø Main bearing journal	Code / code letter
			1 – 5
	Standard size	mm	54.980 - 54.991	1 N
		mm	54.991 - 54.997	0 N
	Undersize (0.25)	mm	54.730 - 54.741	1 U
		mm	54.741 - 54.747	0 U
	Undersize (0.50)	mm	54.482 - 54.491	1 -
		mm	54.491 - 54.495	0 -
			Ø Con-rod bearing journal
			1 – 4
	Standard size	mm	42.971 – 42.987	N
	Undersize (0.25)	mm	42.721 – 42.737	U
	Undersize (0.50)	mm	42.471 – 42.487	-
			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	-

Engine			Z 16 LER / Z16 LEL
Crankshaft bearing			Lower crankshaft bearing shell
1, 2, 4, 5			Colour code	Thickness	Identification
					FGP R25
	Standard size	mm	brown	1.987 – 1.993	136 N
		mm	green	1.993 – 1.999	138 N
	Undersize (0.25)	mm	brown/blue	2.112 – 2.118	140 A
		mm	green/blue	2.118 – 2.124	142 A
	Undersize (0.50)	mm	brown/white	2.237 – 2.243	144 B
		mm	green/white	2.243 – 2.249	146 B
			Upper crankshaft bearing shell
	Standard size	mm	brown	1.987 – 1.993	136 N
		mm	green	1.993 – 1.999	138 N
	Undersize (0.25)	mm	brown/blue	2.112 – 2.118	140 A
		mm	green/blue	2.118 – 2.124	142 A
	Undersize (0.50)	mm	brown/white	2.237 -2.243	144 B
		mm	green/white	2.243 – 2.249	146 B
Perm. crankshaft bearing play		mm	0.0155 - 0.047
Perm. crankshaft end play		mm	0.100 – 0.202
Perm. out-of-round		mm	0.03

Engine			Z 16 LER / Z16 LEL
3 crankshaft bearings			Lower crankshaft bearing shell
(guide bearing)			Colour code	Thickness	Identification
					FGP R25
	Standard size	mm	brown	1.987 – 1.993	150 N
		mm	green	1.993 – 1.999	152 N
	Undersize (0.25)	mm	brown/blue	2.112 – 2.118	154 A
		mm	green/blue	2.118 – 2.124	156 A
	Undersize (0.50)	mm	brown/white	2.237 – 2.243	158 B
		mm	green/white	2.243 – 2.249	160 B
			Upper crankshaft bearing shell
	Standard size	mm	brown	1.987 – 1.993	150 N
		mm	green	1.993 – 1.999	152 N
	Undersize (0.25)	mm	brown/blue	2.112 – 2.118	154 A
		mm	green/blue	2.118 – 2.124	156 A
	Undersize (0.50)	mm	brown/white	2.237 -2.243	158 B
		mm	green/white	2.243 – 2.249	160 B

Engine			Z 16 LER / Z16 LEL
3 wide main bearing journals (guide bearing)			Colour code	Width	Identification
	Standard size	mm	brown	25.850 – 25.900	-
		mm	green
	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

Engine			Z 16 LER / Z16 LEL
Con-rod bearing			Lower con-rod bearing shell
			Colour code	Thickness	Identification
					FGP R30
	Standard size	mm	-	1.485 - 1.493	122 N
	Undersize (0.25)	mm	blue	1.610 – 1.622	123 A
	Undersize (0.50)	mm	white	1.735 – 1.747	124 B
			Upper con-rod bearing shell
					GM S43S
	Standard size	mm	-	1.485 - 1.493	259 N
	Undersize (0.25)	mm	blue	1.610 – 1.622	260 A
	Undersize (0.50)	mm	white	1.735 – 1.747	261 B
Perm. con-rod play		mm	0.027 - 0.071

Illustration

Crank Drive, Cylinder Block

1	Index – identification of cylinder bore
2	Cylinder Bore
3	3-piece oil scraper ring
4	Tapering compression ring
5	Compression ring
6	Piston diameter

Engine				Z 16 LER / Z16 LEL
Ø Cylinder bore
	Standard size
		Index 00	mm	78,992 - 79,008
		Index 05	mm	79,042 - 79,058
	Oversize 1)
		Index 00 + 0.5	mm	79,492 - 79,508
Ø Piston
	Standard size
		Index 00	mm	78,948 - 78,962
		Index 05	mm	78,998 - 79,012
	Oversize
		Index 00 + 0.5	mm	79,448 - 79,462
mean piston clearance			mm	0,045

Engine				Z 16 LER
Piston Rings
	Rectangular compression ring
		Height	mm	1,2 (1,17 - 1,195)
		Gap	mm	0,2 - 0,35
		Vertical play	mm	0,015 - 0,070
	Tapered compression ring
		Height	mm	1,2 (1,17 - 1,19)
		Gap	mm	0,35 - 0,50
		Vertical play	mm	0.03 - 0.07
	Oil scraper ring
		Height	mm	2,0 (1,93 - 1,99)
		Gap	mm	0,2 - 0,9
		Vertical play	mm	0,04 - 0,12
Ring gap distribution 2)			°	120

Engine				Z 16 LER / Z16 LEL
Piston Pins
	Length		mm	53
	Diameter		mm	19
	Bearing			mounted floating
	Play
		in piston	mm	0,005 - 0,015
		in con-rod	mm	0,015 - 0,026

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 23 to 37 mm offset to the left and gap of the lower ring 23 to 37 mm offset to the right relative to the gap of the lower intermediate ring.