vauxhall Workshop Repair Guides

Vauxhall Workshop Service and Repair Manuals

ABOUT US
Positive Crankcase Ventilation Oil Separator Drain Hose Replacement - without Start/Stop System > < Catalytic Converter Brace Bracket Replacement

Astra J

Piston, Connecting Rod, and Bearing Replacement

Special Tools

EN-46785   Fixing Tool

For equivalent regional tools, refer to Special Tools .

Removal Procedure

1. Remove the oil pan. Refer to Oil Pan Replacement .
2. Remove the cylinder head. Refer to Cylinder Head Replacement .
3. Install the engine mount bracket. Refer to Engine Mount Bracket Replacement .

           2191159


4. Remove the 6 oil pan baffle bolts (1).
5. Remove the oil pan baffle (2).

           2191160



Note:  If the EN-46785   fixing tool is installed, remove it.
6. Set the crankshaft to TDC of combustion stroke of cylinder 1.
7. Remove and DISCARD the 4 connecting rod bearing cap bolts (4) from the cylinder 2 and 3.

Note:  Marking (2) of the connecting rod bearing caps. Set aside in the order removed.

Note:  The shear surfaces of the connecting rod and the connecting rod bearing cap form a unique fit and must not be swapped or damaged. Do not lay down on the shear surfaces.
8. Remove the 2 connecting rod bearing caps (3) from the cylinder 2 and 3.

Note:  Set aside in the order removed.
9. Remove the 2 connecting rod lower bearings (1).

           2191163



Note:  Marking (2) of the connecting rod. Set aside in the order removed.
10. Push the 2 pistons with connecting rod (1) from the cylinder 2 and 3 upwards.
11. Remove the 2 connecting rod upper bearings (1) from the cylinder 2 and 3.
12. Turn the crankshaft through 180° and set crankshaft to TDC of combustion stroke of cylinder 2.

           2191164


13. Remove and DISCARD the 4 connecting rod bearing cap bolts (4) from the cylinder 1 and 4.

Note:  Marking (2) of the connecting rod bearing caps. Set aside in the order removed.

Note:  The shear surfaces of the connecting rod and the connecting rod bearing cap form a unique fit and must not be swapped or damaged. Do not lay down on the shear surfaces.
14. Remove the 2 connecting rod bearing caps (3) from the cylinder 1 and 4.

Note:  Set aside in the order removed.
15. Remove the 2 connecting rod lower bearings (1).

           2191165



Note:  Marking (2) of the connecting rod. Set aside in the order removed.
16. Push the 2 pistons with connecting rod (1) from the cylinder 1 and 4 upwards.

Note:  Set aside in the order removed.
17. Remove the 2 connecting rod upper bearings (3) from the cylinder 1 and 4.
18. Disassemble the piston and the connecting rod. Refer to Piston and Connecting Rod Disassemble .

Installation Procedure

1. Assemble piston and connecting rod. Refer to Piston and Connecting Rod Assemble .

           2191881



Note:  Install the 4 connecting rod bearing shells with oil bore (3) into the connecting bearing caps (2).
 If the old connecting rod bearing shells will be reused, install in their original position.
2. Install the 8 connecting rod bearing shells (1).

           2191884


3. The arrow (2) on the piston head must point to the timing side.

Note:  The connecting rod bearing caps must be installed in their original position.
4. Note the marking (1) of the connecting rod and connecting rod cap.
5. The piston ring joints must be displaced 120° to each other.
6. Set the crankshaft to TDC of combustion stroke of cylinder 2.
7. Coat all pistons and cylinder bores with engine oil.

           2191165


8. Install a piston ring compressor in order to compress the piston rings.
9. Install the 2 pistons with connecting rod (1) and connecting rod upper bearing shells (3) into cylinder 1 and 4.

           2191164



Note:  Marking (2) of the connecting rod bearing caps.
10. Install the 2 connecting rod bearing caps (3) with connecting rod lower bearing shells (1) into cylinder 1 and 4.

Caution: Refer to Fastener Caution .
11. Install 4 NEW connecting rod bearing cap bolts (4) to cylinder 1 and 4 and tighten in following order:
  •  Tighten the bolts in first step to 20 N·m (15 lb ft) .
  •  Tighten the bolts to an additional 40° .
12. Turn the crankshaft through 180° and set crankshaft to TDC of combustion stroke of cylinder 1.

           2191163


13. Install a piston ring compressor in order to compress the piston rings.
14. Install the 2 pistons with connecting rod (1) with connecting rod upper bearing shells (3) into cylinder 2 and 3.

           2191160



Note:  Marking (2) of the connecting rod bearing caps.
15. Install the 2 connecting rod bearing caps (3) with the connecting rod lower bearing shells (1) into cylinder 2 and 3.
16. Install 4 NEW connecting rod bearing cap bolts (4) to the cylinder 2 and 3 and tighten in following order:
  •  Tighten the bolts in first step to 20 N·m (15 lb ft) .
  •  Tighten the bolts to an additional 40° .

           2191159


17. Install the oil pan baffle (2).
18. Install the 6 oil pan baffle bolts (1) and tighten to 9 N·m (80 lb in) .
19. Remove the engine mount bracket. Refer to Engine Mount Bracket Replacement .
20. Install the cylinder head. Refer to Cylinder Head Replacement .
21. Install the oil pan. Refer to Oil Pan Replacement .

Positive Crankcase Ventilation Oil Separator Drain Hose Replacement - without Start/Stop System > < Catalytic Converter Brace Bracket Replacement