vauxhall Workshop Repair Guides

Vauxhall Workshop Service and Repair Manuals

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Replacing one piston / con-rod > < Check con-rod bearing clearance (with micrometer)

Astra H

All Pistons with Con-rod, Remove and Install

  Remove

1.   Remove toothed belt
2.   Install support (1) for engine damping block
•   Tighten 4x bolt (M10) 50 Nm
Note:   Note different bolts
•   Tighten bolt (M8) 25 Nm
Object Number: 7360966 Size: DEFAULT


3.   Install right engine damping block (1)
•   Attach to engine damping block support
– Tighten 3x bolt (2) 55 Nm
•   to side member
– Tighten 3x bolt (3) 35 Nm
Object Number: 7360965 Size: DEFAULT


4.   Remove oil pan
5.   Install front axle body
Note:   The old bolts can be used again for installation
6.   Remove cylinder head
7.   Set cylinder 1 to TDC of combustion stroke
8.   Remove 2x con-rod bearing cap (1)
Note:   Note cylinder sequence.
•   Cylinder 2, cylinder 3
•   Mark con-rod with con-rod bearing cover
Important:   The shear surfaces of the con-rod and the con-rod bearing cover form a unique fit and must not be swapped or damaged. Do not lay down on the shear surfaces
•   Unscrew 4x bolts
•   Push 2x piston with con-rod upwards
Object Number: 2408537 Size: DEFAULT


9.   Lower vehicle by its full height
10.   Remove 2x piston
11.   Raise vehicle by its full height
12.   Turn crankshaft
•   180° in direction of engine rotation
13.   Remove 2x con-rod bearing cap
Note:   Note cylinder sequence
•   Cylinder 1, cylinder 4
•   Mark con-rod with con-rod bearing cover
Important:   The shear surfaces of the con-rod and the con-rod bearing cover form a unique fit and must not be swapped or damaged. Do not lay down on the shear surfaces
•   Unscrew 4x bolts
•   Push 2x piston with con-rod upwards
14.   Lower vehicle by its full height
15.   Remove 2x piston
16.   Take off 8x con-rod bearing shell
Note:   Mark con-rod bearing shells. Note sequence

  Install

17.   Visually check components
•   Crank drive
18.   Insert 8x con-rod bearing shell
•   In con-rod, con-rod bearing cap
Note:   Note markings
– Coat with engine oil
19.   Set piston ring gap
•   Adjust 3x piston ring
– Arrange joints offset by 120° (I - III)
Object Number: 2417270 Size: DEFAULT


20.   Install 2x piston
Important:   Arrow on piston head points to engine timing side
•   Coat pistons and cylinder bores with engine oil
– Cylinder 1, cylinder 4
•   Push piston rings together with piston tightening strap
•   Push in piston
21.   Raise vehicle by its full height
22.   Attach 2x con-rod bearing cap
•   Wet 2x con-rod bearing journal with engine oil
Important:   Observe correct allocation and installation position
•   Tighten 4x new bolt 25 Nm + 60°
23.   Turn crankshaft
•   180° in direction of engine rotation
24.   Lower vehicle by its full height
25.   Install 2x piston
Important:   Arrow on piston head points to engine timing side
•   Coat pistons and cylinder bores with engine oil
– Cylinder 2, cylinder 3
•   Push piston rings together with piston tightening strap
•   Push in piston
26.   Raise vehicle by its full height
27.   Attach 2x con-rod bearing cap
•   Wet 2x con-rod bearing journal with engine oil
Important:   Observe correct allocation and installation position
•   Tighten 4x new bolt 25 Nm + 60°
28.   Install cylinder head
29.   Remove front axle body
30.   Install oil pan
31.   Remove engine damping block support
•   Unscrew 4x bolt (M10)
•   Unscrew bolt (M8)
Note:   Note different bolts
32.   Remove engine damping block, right hand side
•   Detach from engine damping block support
– Unscrew 3 bolts
•   From side member
– Unscrew 3 bolts
33.   Install toothed belt

Replacing one piston / con-rod > < Check con-rod bearing clearance (with micrometer)