Opel z22se engine repair

Z22SE

In various modifications, the unit was installed on almost all GM models of that time. Officially, the Z22 engine line was marketed as the “Ecotec Family II Series” and was produced at three plants at once - in Tennessee (Spring Hill Manufacturing), in New York (Tonawanda) and in Kaiserslautern, Germany (Opel components plant).

In Germany and England the engine was designated as Z22SE. In America it was known as the L61 and was installed on a number of Chevrolet, Saturn and Pontiac cars. Under license, the Z22SE was also installed on the Fiat Kroma and Alfa Romeo 159. The line included 2.4 liter engines with a turbocharger, and several other different variations, but we will dwell in more detail on the Z22SE, since it was the founder of the entire series.

General view of the Z22SE under the hood of the Opel Vectra GTS 2.2 BlackSilvia

Specifications Z22SE

Instead of a cast iron BC, the Z22SE used an aluminum BC with a height of 221 mm and two balance shafts designed to reduce vibration of the installation. Inside the block is a crankshaft with a piston stroke of 94.6 mm. The length of the Z22SE connecting rods is 146.5 mm. The distance between the piston crown and the midpoint of the piston pin axis is 26.75 mm. Engine displacement is 2.2 liters.

The aluminum cylinder head hides two camshafts and sixteen valves, with intake and exhaust diameters of 35.2 and 30 mm, respectively. The thickness of the poppet valve stem is 6 mm. ECU Z22SE – GMPT-E15.

*The engine number is located on the BC platform under the oil filter.

In 2007, serial production of the Z22SE was finally stopped and was replaced by the Z22YH power unit.

Opel Z22SE engine malfunctions and repairs

This internal combustion engine began to be produced in 2000, and it replaced the 2-liter X20XEV. An aluminum cylinder block with cast iron liners and two balancer shafts was used here; the block height is 221 mm. Inside it is a crankshaft with a piston stroke of 94.6 mm, the length of the Z22SE connecting rods is 146.5 mm, the piston compression height is 26.75 mm, and the piston diameter is 86 mm. As a result, we have a working volume of 2.2 liters.

This block is covered with an aluminum head with 2 camshafts and 16 valves. The diameter of the intake valves is 35.2 mm, the exhaust valves are 30 mm, the thickness of the valve stem is 6 mm. The characteristics of the camshafts are as follows: phase 245/245 degrees, lift 9.5/9.5 mm. In North America, the Z22SE engine is known as the Chevrolet L61 and was installed in a number of Chevrolet, Saturn and Pontiac vehicles. The weakest versions of the L61 engine were installed on the Saturn L, where, due to puddle pistons, the compression ratio was reduced to 9.5 and camshafts were installed with a different cam profile.

Features of operation, malfunctions and maintenance of Z22SE

The problems of the Z22 engine line were common to all Opel units of that time. Let's look at the main malfunctions of the Z22SE.

pros

• Large motor resource.
• Maintainability.
• Possibility of tuning.

Minuses

• Timing drive.
• Maslozhor.
• Antifreeze in spark plug wells.

When a diesel sound appears in the Z22SE engine, there is a high probability that the timing chain hydraulic tensioner will fail, which usually jams every 20-30 thousand kilometers. The chain drive on the Z22SE is generally one of the most problematic components of this unit.

Due to the poor design of the nozzle installed in it, the chain, shoes, dampers and tensioner are starved of oil.

Signs of an upcoming change in the gas distribution mechanism drive are quite simple - after starting the engine, a clear “diesel” sound is heard (especially at low temperatures), which disappears after a couple of minutes of warming up the engine. In fact, there shouldn't be any clanging. This engine runs a little harder than a belt engine, but is quite balanced. By the way, until 2002, Z22SE engines came with a factory defect - there was not one chain guide. Then, after the chain broke, GM even recalled them and repaired them at its own expense.

Of course, the tensioner can be replaced, but it is better to change the chain drive completely (with all the accompanying parts) before it is too late, because most likely the chain has already been stretched and even jumped a few teeth. At the same time, by the way, you can replace the water centrifugal pump. After repair, if you change the hydraulic tensioners in time, then, as a rule, you can forget about the gas distribution mechanism drive for 100-150 thousand km.

The main reason for the appearance of oil leaks on the Z22SE valve cover, which covers the gas distribution mechanism, lies in the cover itself. Replacing with a new plastic one will probably solve the problem. If the oil leak does not disappear, then the engine is already worn out and needs major repairs.

Z22SE Opel Zafira 2.2

Dips, tripping, or simply uneven operation of the engine may indicate that the spark plugs are filled with antifreeze and this is causing all the problems. The most unpleasant thing that can happen in this case is the formation of a crack in the cylinder head. The price tags for new heads for the Z22SE are quite high, and such defects cannot be treated with traditional argon welding - this is a feature of the cylinder head material of this engine. So it will be cheaper to find a working used head. A very common replacement is a cylinder head from SAAB, which fits onto the Z22SE “like a native one” after some modifications.

Very weak acceleration and lack of dynamics most likely mean that the problem is in the quality of the fuel and the mesh under the fuel pump. Bad gasoline can cause it to become completely clogged with dirt. For cleaning you will need a new gasket under the fuel pump cover. It is advisable to do the procedure on an empty tank in order to at the same time clean the place where the fuel pump itself is located. It will also be possible to check whether it works and whether the hoses are intact. Perhaps the problem lies in the fuel filter.

The exhaust gas recirculation valve is not the most reliable system under operating conditions in the Russian Federation, and it is “jammed” not only on Opels, but almost everywhere where it is available.

Of course, there may be consequences with oxygen sensors, but even here you can get out of the situation with the help of an adapter sleeve.

Usually, by 10 years of use, the catalyst located in the exhaust pipe of the muffler becomes so clogged that gases simply do not pass through. After knocking out the “plug”, even an increase in power of 5-10 hp is possible.

Recommendations from owners of cars with engines

Owners of cars with Opel Z22YH say that not everything is as sad as official sources claim. For example, constant problems with timing chains and balance shafts (which are considered the most important problem with internal combustion engines) are mostly far-fetched. They only affect those owners who ignore regular technical inspections and generally take care of their cars.

The unit warns even the most careless driver long before trouble arises. It starts to “diesel” on a cold engine and disappears when warming up, making it difficult to start. Ignoring hints leads to a broken circuit and serious repairs.

Low-quality gasoline and oil are dangerous for all engines, Opel Z22YH fans specify. You just need to fill up fuel only at proven gas stations, then everything will be fine. And a large number of detergent additives will kill any internal combustion engine.

In general, contrary to the opinion of the Opel company, users of the Opel Z22YH engine in Russia do not consider all its shortcomings to be so critical. They appreciate the unpretentious and durable engine, and take diligent care of it. They are only upset by the inability to purchase new parts for major repairs.

Conclusion: It would be wisest to use the Opel Z22YH engine until about ¾ of its service life, and then change the car to an option with a newer engine.

With regular care and maintenance, the resource will be 400-600 thousand kilometers. Some lucky ones reached almost a million.

A major overhaul makes no sense; putting one together from two is too expensive. Carry out ongoing minor repairs and wait for the opportunity to buy something modern. ICE maintenance costs minimally, but it is better to have it every 20-30 thousand km. Then the engine will remain in good condition longer.

Source

Analogs of spare parts for the Z22SE engine

The Z22SE is very common in America, because it was not only produced there, but also installed on a wide range of cars intended for the local market. Consumables and parts that are sold for a lot of money in Europe can be easily found and purchased in the USA at an affordable price through the same EBAy service. For example, an original ignition coil, the price of which in Russia starts at 7 thousand rubles, can be ordered in the states for $50.

Instead of the stock antifreeze temperature regulator in the Z22SE engine cooling system, a thermostat from the VW Passat B3 1.8RP, which has exactly the same dimensions and opening temperature, is perfect. And its main advantage is that it is produced by almost all famous manufacturers, and costs around 300-400 rubles. The same Gates and HansPries consistently jam closed in the summer, or they “bleed through” in the winter. An original thermostat costs from 1.5 thousand rubles.

Z22SE in the engine compartment of the Opel Astra G

The original cylinder head does not have the best casting quality due to technology, so the Z22SE cylinder head is completely unrepairable. Cracks often appear on it, which cannot be repaired for a long time. You can install a cast head from the 2.0T-B207L unit installed in the SAAB 9-3. Engines 2.2 and 2.0T are almost the same. They differ only in volume and the presence of turbocharging, other parts are interchangeable.

With minor modifications, this cylinder head easily fits in place of the standard one.

Also, Siemens injectors from the 406th GAZ are excellent for the Z22SE engine - their characteristics are identical to those that go to the 2.2 engine from the factory. Given the difference in price between the original injectors and those for the Volga, it’s not scary that the latter will last, say, only a year.

Tuning Z22SE

In the case of the Z22SE, budget, and at the same time good, tuning will not work, so those who decide to modify this engine should immediately prepare for large financial expenses.

You can slightly increase the power of the unit with minimal investment by removing the balance shafts, as well as installing a manifold and damper from LE5 on the intake. Afterwards, it is advisable to install a “4-2-1” manifold on the exhaust, which operates in a wider speed range, and “finalize” all this by adjusting the ECU.

Turbocharged Z22SE under the hood of the Astra Coupe

To obtain much greater power, you will have to install a cold air supply system (in a pre-installed manifold from LE5), install a large damper from LSJ, injectors from Z20LET, Piper 266 camshafts with springs and plates. In addition, it will be necessary to port the cylinder head, install 36 mm valves on the intake and 31 mm on the exhaust, install a lightweight flywheel, a “4-2-1” exhaust and forward flow on a 63 mm pipe. For all this hardware, you will need to properly configure the ECU and then you can get up to 200 hp on the Z22SE flywheel.

It is not profitable to look for even greater power in the Z22SE - a good turbo kit mounted on this engine costs more than the car itself on which it is installed.

Tuning Opel Z22SE engines

There is no budget tuning for the Z22SE, so get ready to spend money right away. You can increase the power of your 2.2-liter engine extremely cheaply by removing the balancer shafts, as well as installing an intake manifold from a Chevrolet LE5 and a damper from it. It is advisable to install a 4-2-1 manifold for the exhaust and you need to configure the control unit for all this. To get significantly more power you need to install a cold intake, an intake manifold from a Chevrolet LE5, a larger throttle body (for example, from an LSJ), Z20LET injectors, Piper 266 camshafts with springs and discs, you need to port the cylinder head and install +1 mm valves (intake 36 mm, 31 mm exhaust), remove balancer shafts, install a lightweight flywheel, 4-2-1 exhaust manifold, direct exhaust on a 63 mm pipe. For all this you need to configure the control unit and you can get up to 200 hp. on the flywheel. Making more power is not profitable - turbo kits with installation cost more than a car.