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Air Conditioning Compressor Bracket Replacement > < Engine Oil and Oil Filter Replacement

Astra J

Piston, Connecting Rod, and Bearing Replacement

Special Tools

EN-470-B   Angular Torque Wrench

For equivalent regional tools, refer to Special Tools .

Removal Procedure

1. Open the hood.
2. Remove the cylinder head. Refer to Cylinder Head Replacement .
3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
4. Remove the oil pan. Refer to Oil Pan Replacement .

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Note:  Mark the installation position of the connecting rod bearing caps. The connecting rod bearings and bearing caps must not be interchanged with other connecting rods.
5. Remove and DISCARD the 4 connecting rod bearing cap bolts (1) of cylinder 2 and 3.
6. Remove the 2 connecting rod bearing caps (2) and the 2 connecting rod bearings of cylinder 2 and 3.
7. Rotate the crankshaft 180° .

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8. Remove and DISCARD the 4 connecting rod bearing cap bolts (1) of cylinder 1 and 4.
9. Remove the 2 connecting rod bearing caps (2) and the 2 connecting rod bearings of cylinder 1 and 4.

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10. Remove the 4 pistons (1) and connecting rods (2) and the 4 upper connecting rod bearings (3) from the cylinder block.

Installation Procedure

1. For cleaning and inspection procedure, refer to Piston, Connecting Rod, and Bearing Cleaning and Inspection .
2. Assemble the NEW piston and connecting rod. Refer to Piston and Connecting Rod Assemble .

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3. Adjust the piston ring joints as followed:
  3.1 Upper compression ring (1)
  3.2 Lower compression ring (4)
  3.3 Oilring (2) or (3)
  3.4 Oilring spacer (5)

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4. The arrow (1) on the piston head must point to the timing side.
5. The markings on the connecting rods (2) must point to the transmission side.

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6. Lubricate the piston rings, piston, inner cylinder bore surface and a piston ring compressor with clean engine oil.
7. Install the piston ring compressor in order to compress the piston rings.
8. Install the pistons (1) in compound with connecting rods (2) and upper connecting rod bearings (3) to the engine block and to the crankshaft.

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Note:  The flarings (arrows) on the connecting rod bearing caps must point to the transmission side. The connecting rod bearing caps must be installed in their original position.
9. Install the 2 connecting rod bearings and the 2 connecting rod bearing caps (2) of cylinder 1 and 4.

Caution: Refer to Fastener Caution .
10. Install the 4 NEW connecting rod bearing cap bolts (1) and tighten in the following sequence:
  10.1 Tighten the connecting rod bearing cap bolts to 25 N·m (18 lb ft) .
  10.2 Tighten the connecting rod bearing cap bolts an additional 25° . Use EN-470-B   wrench .
11. Rotate the crankshaft 180° .

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Note:  The flarings (arrows) on the connecting rod bearing caps must point to the transmission side. The connecting rod bearing caps must be installed in their original position.
12. Install the 2 connecting rod bearings and the 2 connecting rod bearing caps (2) of cylinder 3 and 2.

Caution: Refer to Fastener Caution .
13. Install the 4 NEW connecting rod bearing cap bolts (1) and tighten in the following sequence:
  13.1 Tighten the connecting rod bearing cap bolts to 25 N·m (18 lb ft) .
  13.2 Tighten the connecting rod bearing cap bolts an additional 45° . Use EN-470-B   wrench .
14. Install the oil sump Refer to Oil Pan Replacement .
15. Lower the vehicle.
16. Install the cylinder head. Refer to Cylinder Head Replacement .
17. Close the hood.

Air Conditioning Compressor Bracket Replacement > < Engine Oil and Oil Filter Replacement