Specifications of the 1.6L DOHC petrol engine (Opel Vectra B)

Cylinder head
Maximum permissible non-flatness of the lower surface of the head cylinder block	0.05 mm
Cylinder head height	135 mm
Valve seat width:
- inlet valve	1.0 – 1.4 mm
- exhaust valve	1.4 – 1.8 mm
Piston pins
Diameter	18 mm
Length	55 mm
Piston pin clearance in piston	0.007 – 0.010 mm
Crankshaft
Axial play	0.1 – 0.2 mm
Main journal diameters:
– nominal size	54.980 – 54.997 mm
– 1st repair size – 0.25	54.730 – 54.747 mm
– 2nd repair size – 0.50	54.482 – 54.495 mm
Connecting rod journal diameters:
– nominal size	42.987 – 42.971 mm
– 1st repair size – 0.25	42.721 – 42.737 mm
– 2nd repair size – 0.50	42.471 – 42.487 mm
Maximum ovality	0.04 mm
Maximum taper	N/ A
Main bearing working clearance	0.017 – 0.047 mm
Operating clearance of the lower connecting rod bearing	0.019 – 0.071 mm
Cylinder block
Maximum permissible non-flatness	0.05 mm
Cylinder diameters:
- standard:
• size group 5	78.945 – 78.955 mm
• size group 6	78.955 – 78.965 mm
• size group 7	78.965 – 78.975 mm
• size group 8	78.975 – 78.985 mm
• size group 99	78.985 – 78.995 mm
• size group 00	78.995 – 79.005 mm
• size group 01	79.005 – 79.015 mm
• size group 02	79.015 – 79.025 mm
• size group 03	79.025 – 79.035 mm
• size group 04	79.035 – 79.045 mm
• size group 05	79.045 – 79.055 mm
• size group 06	79.055 – 79.065 mm
• size group 07	79.065 – 79.075 mm
• size group 08	79.075 – 79.085 mm
• size group 09	79.085 – 79.095 mm
• size group 1	79.095 – 79.105 mm
– increased size (0.5 mm)	79.465 – 79.475 mm
Maximum ovality and taper of engine cylinder diameter	0.013 mm
Pistons and rings
Piston diameter:
- standard:
• size group 5	78.915 – 78.955 mm
• size group 6	78.925 – 78.935 mm
• size group 7	78.935 – 78.945 mm
• size group 8	78.945 – 78.955 mm
• size group 99	78.955 – 78.965 mm
• size group 00	78.965 – 78.075 mm
• size group 01	78.075 – 78.085 mm
• size group 02	78.085 – 78.095 mm
• size group 03	78.095 – 79.005 mm
• size group 04	79.005 – 79.015 mm
• size group 05	79.015 – 79.025 mm
• size group 06	79.025 – 79.035 mm
• size group 07	79.035 – 79.045 mm
• size group 08	79.045 – 79.055 mm
• size group 09	79.055 – 79.065 mm
• size group 1	79.065 – 79.075 mm
– larger size (0.5 mm) – size group 7 + 0.5	79.435 – 79.445 mm
Piston clearance in cylinder	0.02 – 0.04 mm
Piston ring lock clearances (installed in the hole):
- upper and lower sealing rings	0.3 – 0.5 mm
- oil scraper ring	0.4 – 1.4 mm
Piston ring thickness:
- upper sealing ring	1.2 mm
- lower sealing ring	1.5 mm
- oil scraper ring	2.5 mm
Connecting rod
Lower connecting rod end side clearance	0.11 – 0.24 mm
Valves
Height of valve guide bushing in cylinder head	10.70 – 11.00 mm
Valve stem diameter:
– inlet valve:
• nominal (K)	5.995 to 5.970 mm
• 1st size up (0.075 mm – K1)	6.030 to 6.045 mm
• 2nd larger size (0.150 mm– K2)	6.150 to 6.165 mm
– exhaust valve:
• nominal (K)	5.935 to 5.950 mm
• 1st size up (0.075 mm – K1)	6.010 to 6.025 mm
• 2nd larger size (0.150 mm – K2)	6.085 to 6.100 mm
Valve stem outlet	less than 0.03 mm
Valve guide bore diameter:
– nominal (K)	from 6.000 to 6.012 mm
– 1st increased size (0.075 mm – K1)	6.075 to 6.090 mm
– 2nd larger size (0.150 mm – K2)	6.150 to 6.165 mm
Clearance between valve stem and valve guide	N/ A
Valve length:
- inlet valve	103.1 mm
- exhaust valve	102.2 mm
Valve Plate Diameter:
- inlet valve	31.0 mm
- exhaust valve	27.5 mm

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Opel Vectra B: Engine repair

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