Vauxhall Workshop Service and Repair Manuals

Remove oil pan – see operation "Oil Pan, Remove and Install".

Remove cylinder head – see operation "Cylinder Head, Remove and Install".

Remove oil intake pipe.

Remove bearing bridge attachment screws (1) and (2). Remove bearing bridge (3).

Caution

Make note of piston, con-rod and bearing shell installation positions. Con-rod and con-rod bearing cover (4) are marked with same pairing number (5).

  Clean

Remove oil carbon at upper cylinder edge.

Remove con-rod bearing cover (2) from con-rod (3). Put con-rod bearing cover and con-rod bearing shells to one side in cylinder order. Push piston out of the top using con-rod.

Caution

Independently of the colour mark (1), a red and a blue con-rod bearing shell must be installed per con-rod. The con-rod bearing shells, blue or red, can be arbitrarily inserted in the con-rod or in the con-rod bearing caps.

  Install

Insert Guide KM-828 (4) into con-rod.

  Install

Lightly oil piston and piston rings. Offset piston ring joints by approx. 120°, but do not position them over the eye of the piston pin. The piston ring joint of the double-bevelled ring must be offset 180° to the opening of the inner hose spring.

Compress piston rings with piston ring tensioning band (1). Arrow on piston head points towards engine timing side. Insert piston with con-rod.

The crankshaft journal of the relevant cylinder must be in the "TDC or BDC position".

Entire circumference of piston ring compressor must lie firmly on cylinder block. Carefully push piston into cylinder using hammer shaft.

Position piston and con-rod up to the crankshaft journal using Guide KM-828 (2). Remove Guide KM-828.