Vauxhall Workshop Service and Repair Manuals

Connecting Rod , Replace

Remove piston.

See corresponding operation in this group.

Press out wrist pin using Remover KM-427.

When doing this, support piston at wrist pin recess with a pipe.

If piston is properly supported, it will not be damaged and can be reused.

Heat new connecting rod to assembly temperature of 280 °C / 536 °F in electric oven or on hot plate (1,500 to 2,000 W).

Temperature can be checked using a thermocolour pencil.

Upper eye of connecting rod is placed on hot plate.

In order to ensure quick and uniform heating, surface of eye must lie absolutely flat on hot plate.

To avoid heat loss, laying a firebrick on the connecting rod eye is recommended.

Colour connecting rod eye and upper section of shaft with temperature indicator pencil.

When connecting rod reaches 280 °C/536 °F, original green colour changes to black, indicating that desired assembly temperature has been reached.

Ensure that colour does not change along its entire length, but only as far as beginning of connecting rod shaft.

Select new piston according to tables in Technical Data.

If stamped size marking on piston cannot be deciphered, measure piston diameter 15 mm/0.59 in. above lower shaft end and at right angles to shaft with a micrometer.

After assembly temperature has been reached, place connecting rod in a vice using minimal pressure. Insert guide cone and Installer KM-427 in wrist pin (lubricated with engine oil) and guide into piston bore. Piston contacts connecting rod in direction of pressure of wrist pin.

Guide piston over connecting rod so that recess on piston is on same side as lug on connecting rod.

Push wrist pin into connecting rod until Installer contacts piston skirt.

Wrist pin must be pushed into piston quickly and smoothly.

Important:

The connecting rod cools quickly: rapid assembly is therefore the determinant factor for perfect seating of the wrist pin.

Wrist pin cannot be adjusted once properly seated.

Only connecting rods of the highest weight class are supplied as spare parts. The weight of a connecting rod can easily be matched to the weight of the rods in the engine by grinding down the two weight bosses.

The maximum permissible difference in weight between connecting rods on one engine is 8 g / 0.28 oz.

See Technical Data for table of connecting rod weights.

Install piston.