Opel Z22SE engine
Content
Serial production of power units under the factory marking Z22SE began in 2000. This engine replaced the two-liter X20XEV and was a development of engineers from General Motors, Opel's ITDC, the American GM Powertrain and the Swedish SAAB. The final refinement of the engine was already being worked on in Britain, in the Lotus engineering building.
Z22SE
In various modifications, the unit was installed on almost all GM models of that time. Officially, the Z22 engine line was called the “Ecotec Family II Series” and was produced at three factories at once - in Tennessee (Spring Hill Manufacturing), in New York (Tonawanda) and in German Kaiserslautern (Opel component manufacturing plant).
In Germany and England, the engine was designated as - Z22SE. In America, it was known as - L61 and was installed on a number of Chevrolet, Saturn and Pontiac cars. Under license, the Z22SE was also installed on the Fiat Krom and Alfa Romeo 159. The lineup included 2.4 liter engines with a turbocharger, and several different variations, but we will dwell on the Z22SE in more detail, since it was he who was the founder of the entire series.
Specifications Z22SE
Instead of a cast iron BC, the Z22SE used an aluminum BC 221 mm high and with two balance shafts designed to reduce machine vibrations. Inside the block is a crankshaft with a piston stroke of 94.6 mm. The length of the Z22SE cranks is 146.5 mm. The distance between the piston crown and the midpoint of the piston pin axis is 26.75 mm. The working volume of the engine 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.
| Features of the Z22SE | |
|---|---|
| Volume cm3 | 2198 |
| Max power, hp | 147 |
| Max torque, Nm (kgm)/rpm | 203 (21) / 4000 |
| 205 (21) / 4000 | |
| Fuel consumption, l / 100 km | 8.9-9.4 |
| A type | V-shaped, 4-cylinder |
| Cylinder Ø, mm | 86 |
| Max power, hp (kW)/r/min | 147 (108) / 4600 |
| 147 (108) / 5600 | |
| 147 (108) / 5800 | |
| Compression ratio | 10 |
| The piston stroke, mm | 94.6 |
| Makes and models | Opel (Astra G/Holden Astra, Vectra B/C, Zafira A, Speedster); |
| Chevrolet (Alero, Cavalier, Cobalt, HHR, Malibu); | |
| Fiat (Croma); | |
| Pontiac (Grand Am, Sunfire); | |
| Saturn (L, Ion, View); | |
| and more | |
| Resource, outside. km | 300+ |
* The engine number is located on the site of the business center under the oil filter.
In 2007, the serial production of the Z22SE was finally stopped and it was replaced by the Z22YH power unit.
Features of operation, malfunctions and maintenance of the Z22SE
The problems of the Z22 engine line are common to all Opel units of that time. Consider the main malfunctions of the Z22SE.
pros
- Great motor resource.
- Maintainability.
- Possibility of tuning.
Cons
- Timing drive.
- Maslozhor
- Antifreeze in spark plug wells.
When a diesel sound appears in the Z22SE engine, there is a high probability of failure of the timing chain tensioner, 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 unsuccessful design of the nozzle installed in it, oil starvation of the chain, shoes, dampers and tensioner occurs.
The signs of an upcoming change in the timing gear 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 should be no clanging. This engine runs a little harder than a belt, but is quite balanced. By the way, until 2002, the Z22SE motors "came" with factory defects - there was not one chain damper. Then, after a chain break, GM even recalled them and repaired them at its own expense.
Of course, the tensioner can be replaced, but it's better to change the chain drive completely (with all related parts) before it's too late, because most likely the chain is already 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 drive of the gas distribution mechanism for 100-150 thousand km.
The main reason for the appearance of oil smudges on the Z22SE valve cover, which closes the gas distribution mechanism, lies in itself. Replacing it with a new, plastic one may solve the problem. If the oil leak does not disappear, then the motor is already worn out and needs to be overhauled.
Failures, tripling, or simply uneven operation of the engine may indicate that the candles are filled with antifreeze and this is 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 for the cylinder head from SAAB, which gets on the Z22SE “like a native” after some modifications.
Very weak acceleration and lack of dynamics most likely mean that the problem is in the quality of fuel and the mesh under the fuel pump. From bad gasoline, it can be 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 clean the place where the fuel pump itself stands at the same time. You can also check if it works and if 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.
Of course, consequences with oxygen sensors are possible, but even here you can get out of the situation with the help of an adapter sleeve.
Usually, by 10 years of mileage, the catalyst located in the exhaust pipe of the muffler becomes so clogged that the gases simply do not pass. After knocking out the “cork”, even an increase in power by 5-10 hp is possible.
Analogs of spare parts for the Z22SE engine
The Z22SE is very common in America, because it was not only produced there, but also put 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 bought in the USA for an acceptable price tag through the same EBAy service. For example, the original ignition coil, the price of which in Russia starts from 7 thousand rubles, can be ordered in the states for $50.
Instead of the stock antifreeze temperature controller in the Z22SE engine cooling system, the thermostat from the VW Passat B3 1.8RP is excellent, which has exactly the same dimensions and opening temperature. And its main plus, it is produced by almost all eminent manufacturers, and costs around 300-400 rubles. The same Gates and HansPries stably jammed closed in the summer, or they "penetrate" in the winter. The original thermostat costs from 1.5 thousand rubles.
The original cylinder head is not the best casting quality due to technology, so the Z22SE cylinder head is completely unrepairable. Cracks often appear on it that cannot be welded for a long time. It is possible to supply 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, such a cylinder head easily takes the place of the regular one.
Also, Siemens injectors from the 22th GAZ are excellent for the Z406SE engine - in terms of characteristics, they are identical to those that go to the 2.2 engine from the factory. With the difference in price between the original nozzles and those for the Volga, it’s not scary that the latter will last, say, only a year.
Tuning Z22SE
Budget, and at the same time good, tuning in the case of the Z22SE will not work, so for those who decide to modify this engine, it is better to immediately prepare for large financial costs.
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 the LE5 on the intake. After that, it is advisable to put a “4-2-1” collector on the outlet, which operates in a wider range of revolutions, and “finish” all this with the ECU setting.
To get much more power, you will have to mount a cold air supply system (into a pre-installed manifold from LE5), install a large damper from LSJ, nozzles from Z20LET, Piper 266 camshafts with springs and plates. In addition, it will be necessary to deal with the porting of the cylinder head, put 36 mm valves on the inlet, and 31 mm on the outlet, install a lightweight flywheel, a 4-2-1 outlet and forward flow on a 63 mm pipe. Under all this hardware, you will need to correctly configure the ECU, and then on the Z22SE flywheel you can get under 200 hp.
Looking for even more power in the Z22SE is unprofitable - a good turbo kit mounted on this engine costs more than the car on which it is installed.
Conclusion
Engines of the Z22SE series are quite reliable power units with a high motor resource. Naturally, they are not ideal. Of the negative qualities of these motors, the cylinder block, which is completely made of aluminum, can be noted. This BC is beyond repair. The Z22SE chain drive generally horrifies many motorists who have dealt with it, since engineers have done a little tricky with its design, although if it is serviced on time, there will be no questions.
Unlike most Opel cars, the Z22SE timing drive works with a single-row chain, which on average “walks” about 150 thousand km.
However, in the same Germany or the USA, for example, such engines easily “run” 300 thousand km without replacing consumables and unnecessary noise. The main role here is played by the climatic conditions of operation of the Z22SE.
Well, in general, the Z22SE motor is a completely ordinary unit that will not leave indifferent any motorist. It needs to be serviced regularly (every 15 thousand km, but many advise doing this more often - after a run of 10 thousand km), use original spare parts and good gasoline. And of course, you always need to monitor the quality of the oil and its level.
