The steps below are shortened from the Vauxhall TIS pages for the Speedster. The VX220 shares the same engines and most of the car, but check anything unusual against your own car. The TIS pictures and the full wording aren't reproduced, so use the workshop manual if you are doing the job. We haven't seen owners' accounts of this job, so there are no owner tips here.
Engine-out work. Clearances are on Turbo engine data and torques on Torque values.
A four post hoist must be used to raise the vehicle when removing the engine undertray and exhaust pipe undertray. The vehicle can be moved to a two post hoist for other operations if required.
Other jobs from the same factory chapter: Crankshaft seals, pulley, sprocket and pulse sensor (Turbo); Balancer shaft unit and backlash (Turbo); Pistons, con-rods and piston rings (Turbo).
Crankshaft: replacement
Turbo (Z20LET) only.
Remove
- Attach engine with Adapter KM-412-8-A to Engine Overhaul Stand KM-412 – remove necessary attaching parts.
- Remove transmission from cylinder block.
- Remove oil pump – see "Oil Pump, Replace".
- Remove upper part of oil pan – see "Oil Pan, Upper, Replace".
- Remove balancer shaft unit – see "Balancer Shaft Unit, Replace".
- Lock flywheel with KM-652 and remove from crankshaft.
- Mark order of con-rod bearing caps – bead points to transmission side.
- Remove con-rod bearing cap from con-rod.
- Mark the order of the crankshaft bearing caps and remove from cylinder block.
- Remove crankshaft from cylinder block.
Clean
- Clean all parts.
Inspect
- Check crankshaft - see "Crankshaft, Out-of-round, Check".
Install
- When replacing crankshaft: transfer crankshaft pulse pickup sensor disc with new bolts - tightening torque 13 Nm
- Coat new bearing shells with engine oil and insert in cylinder block and bearing caps. Carefully insert crankshaft in cylinder block. The seating of the crankshaft can be corrected by light blows on the crank webs with a rubber hammer. Apply bead of adhesive sealing compound (black) to grooves of the crankshaft rear main bearing cap. Install crankshaft and con-rod bearing caps - note identification.
- Crankshaft bearing caps to cylinder block 50 Nm + 45° + 15°
- Important: Use new fastening bolts.
- Note: After assembly of rear main bearing cap, press in adhesive sealing compound (black) from above again until it escapes from the joints.
- Con-rod bearing caps to con-rod 35 Nm + 45° + 15°
- Important: Use new fastening bolts.
- Install rear crankshaft oil seal – see "Crankshaft Oil Seal, Flywheel Side, Replace".
- Install balancer shaft unit – see "Balancer Shaft Unit, Replace".
- Install upper part of oil pan – see "Oil Pan, Upper, Replace".
- Install oil pump – see "Oil Pump, Replace".
- Attach transmission to cylinder block – tightening torque 60 Nm
Crankshaft bearing clearance: micrometer method
Turbo (Z20LET) only.
Remove
- Note: The crankshaft is removed.
- Install crankshaft bearing cap with crankshaft bearing shell at cylinder block - tightening torque 50 Nm + 45° + 15°. To check the crankshaft bearing play, bolt can be reused.
Measure
- The average crankshaft bearing diameter is determined using an inside micrometer at points I, II and III and then calculated.
- Formula for calculating the average crankshaft bearing diameter:
- I + II + III
- Example:
- 54.972 mm
- 54.981 mm
- + 54.984 mm
- 164.937 mm
- ÷ 3 = 54.979 mm
- The average crankshaft bearing diameter is 54.979 mm.
- The crankshaft journal diameter is measured with a micrometer at points I and II and then calculated.
- Formula for calculating the average crankshaft bearing journal diameter:
- I + II
- Example:
- 54.962 mm
- + 54.964 mm
- 109.926 mm
- ÷ 2 = 54.963 mm
- The average crankshaft journal diameter is 54.963 mm.
- The crankshaft play is calculated from the difference in diameter between the crankshaft bearing bore and crankshaft journal.
- Example:
- Average crankshaft bearing diameter
- 54.979 mm
- Average crankshaft journal diameter
- - 54.963 mm
- 0.016 mm
- Permissible crankshaft bearing play: 0.015 to 0.043 mm.
Crankshaft bearing clearance: Plastigage method
Turbo (Z20LET) only.
Inspect
- Bearing play - bearing cover removed.
- Caution
- Clean crankshaft journal and crankshaft bearing shell and lubricate slightly so that thread does not tear when bearing cap is removed. Do not turn crankshaft.
Measure
- With "Plastigage" (deformable plastic thread).
- Cut strip to width of bearing and lay axially between crankshaft bearing journal and bearing shell (arrow). Attach bearing cap with torque - tightening torque 50 Nm + 45° + 15°.
- Note: The bolts can be reused for checking crankshaft bearing play.
- Compare width of flattened plastic thread (arrow) with measuring scale.
- "Plastigage" is available for various measuring ranges.
- Perm. crankshaft bearing play: 0.015 to 0.043 mm.
- Note: When reading the value, do not confuse millimetres with inches on the measuring scale.
- Torque-angle method
- Attach crankshaft bearing cap to cylinder block with new bolts - 50 Nm + 45° + 15°.
Remove
- Remove bearing cover.
Con-rod bearing play: micrometer method
Turbo (Z20LET) only.
Install
- Note: Con-rod and crankshaft are removed.
- Install con-rod bearing cap with con-rod bearing shell to con-rod - Tightening torque 35 Nm + 45° + 15°.
- The bolts can be reused for checking the con-rod bearing play.
Measure
- Formula for calculating the average con-rod bearing diameter:
- I + II + III
- Example:
- 42.738 mm
- 42.732 mm
- + 42.741 mm
- 128.211 mm
- ÷ 3 = 42.737 mm
- The average con-rod bearing diameter is 42.737 mm.
- The con-rod bearing journal diameter is measured with a micrometer at points I and II and then calculated.
- Formula for calculating the average con-rod bearing journal diameter:
- I + II
- Example:
- 42.729 mm
- + 42.725 mm
- 85.454 mm
- ÷ 2 = 42.727 mm
- The average con-rod bearing journal diameter is 42.727 mm. The con-rod bearing play is calculated from the difference in diameter between the con-rod bearing bore and the con-rod bearing journal.
- Example:
- Average con-rod bearing diameter
- 42.737 mm
- Average con-rod bearing journal diameter
- - 42.727 mm
- 0.010 mm
- Permissible con-rod bearing play: 0.006 to 0.031 mm.
Con-rod bearing play: Plastigage method
Turbo (Z20LET) only.
Measure
- Mark installation position of con-rod bearing cap - remove con-rod bearing cap from con-rod.
- Caution
- To prevent the strip from tearing when removing the con-rod bearing cap, remove grease from the con-rod journal and lightly oil con-rod bearing shell. Do not turn the crankshaft.
- Route Plastigage (malleable plastic strip) over the entire width of the con-rod bearing journal.
- Torque-angle method
- Attach con-rod bearing cap to con-rod - tightening torque 35 Nm + 45° + 15. To check the con-rod bearing play, the bolts can be used once again.
- Remove con-rod bearing cap again. Compare width of flattened plastic thread (arrow) with measuring scale.
- Permissible con-rod bearing play: 0.006 to 0.031 mm.
- Note: When reading the value, do not confuse millimetres and inches on the measuring scale.
Install
- Clean con-rod bearing journal and con-rod bearing shell and lubricate lightly.
- Attach con-rod bearing cap to con-rod with new bolts - note installation position of con-rod bearing cap - tightening torque 35 Nm + 45° + 15°.