vauxhall Workshop Repair Guides

Vauxhall Workshop Service and Repair Manuals

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Piston Rings, Replace > < Check crankshaft bearing clearance (with micrometer gauge internal measuring device)

Astra H

Piston with Con-rod, Remove and Install

  Remove

1.   Remove cylinder head
2.   Remove oil dipstick
3.   Raise vehicle by its full height
4.   Place collecting basin underneath.
5.   Drain engine oil
•   Unscrew oil drain bolt (3)
•   Replace gasket
•   Tighten oil drain bolt 78.4 Nm
6.   Detach lower part of oil pan (1) from upper part of oil pan (2) with KM-J-37228
•   Unscrew 15x bolts
Object Number: 2416063 Size: DEFAULT


7.   Remove front exhaust pipe
•   Detach from start-up catalytic converter
– Remove 3x nut (1)
•   Detach from central silencer
– Release clamp (2)
Object Number: 2412700 Size: DEFAULT


8.   Detach oil dipstick guide tube from upper part of oil pan
•   Unscrew 2x bolts (1)
Object Number: 2413384 Size: DEFAULT


9.   Disconnect engine oil level sensor wiring harness plug (1)
Object Number: 3447357 Size: DEFAULT


10.   Detach upper part of oil pan from cylinder block
•   Unscrew bolt (2) and (3)
•   Unscrew nut (1)
•   Separate upper part of oil pan from cylinder block with a broad spatula
Object Number: 2416064 Size: DEFAULT


11.   Remove con-rod bearing cap
•   Cylinder 2 and 3
– Detach 4x screw connections (1)
•   Remove con-rod bearing cap
Note:   Note identification mark on con-rod bearing cap and con-rod. Apply identification mark if not present
•   Push piston upwards
Object Number: 2411088 Size: DEFAULT


12.   Turn crankshaft
•   Turn (180°) in direction of engine rotation
13.   Remove con-rod bearing cap
•   Cylinder 1 and 4
– Detach 4x screw connections (1)
•   Remove con-rod bearing cap
Note:   Note identification mark on con-rod bearing cap and con-rod. Apply identification mark if not present
•   Push piston upwards
Object Number: 2411090 Size: DEFAULT


14.   Lower vehicle by its full height
15.   Take out 4x piston
•   Remove combustion residue
16.   Remove con-rod bearing shells from con-rod and con-rod bearing cap
Note:   Mark con-rod bearing shells and set aside in order
17.   Visually check components
•   Crank drive, valve control, cylinder head, cylinder block, exhaust manifold, turbocharger, valve drive, ribbed V-belt drive

  Install

18.   Install con-rod bearing shells
Note:   Note marking
19.   Adjust piston rings
•   Arrange joints of piston rings offset by 120°
– I Rectangular compression ring (first compression ring)
– II Tapered compression ring (second compression ring)
– III bevelled cap ring (oil scraper ring)
Object Number: 2416037 Size: DEFAULT


Important:   Marking (1) on piston head and marking (2) on con-rod point towards the engine timing side
20.   Install piston with con-rod in cylinder block
•   Cylinder 1 and 4
– Coat with engine oil
•   Force piston rings together with piston ring tensioning belt
– Coat with engine oil
•   Push in piston
Object Number: 2411089 Size: DEFAULT


21.   Raise vehicle by its full height
Important:   Note cylinder sequence marking on con-rod bearing cap and con-rod. Narrow bead (arrow) points towards engine timing side
22.   Install con-rod bearing cap
•   Tighten 2x new screwed joint 24.5 Nm + 100° + 15°
Object Number: 2411091 Size: DEFAULT


23.   Turn crankshaft
•   Turn (180°) in direction of engine rotation
24.   Lower vehicle by its full height
Important:   Marking (1) on piston head and marking (2) on con-rod point towards the engine timing side
25.   Install piston with con-rod in cylinder block
•   Cylinder 2 and 3
– Coat with engine oil
•   Force piston rings together with piston ring tensioning belt
– Coat with engine oil
•   Push in piston
Object Number: 2411089 Size: DEFAULT


26.   Raise vehicle by its full height
Important:   Note cylinder sequence marking on con-rod bearing cap and con-rod. Narrow bead (arrow) points towards engine timing side
27.   Install con-rod bearing cap
•   Attach 2x new screwed joint 24.5 Nm + 100° + 15°
Object Number: 2411091 Size: DEFAULT


28.   Clean sealing surfaces.
29.   Apply sealing compound
30.   Install upper part of oil pan
•   Apply a bead of silicone sealant (grey) to the sealing surface of the upper part of the oil pan
•   Tighten 18x bolt 9.8 Nm
31.   Connect engine oil level wiring harness plug
32.   Attach oil dipstick guide tube to upper part of oil pan
•   Replace gasket
•   Tighten 2x bolts 9.8 Nm
33.   Install front exhaust pipe
•   Attach to start-up catalytic converter
– Replace gasket
– Tighten 3x new nuts
•   Attach to central silencer
– Fasten clamp
34.   Clean sealing surfaces.
35.   Apply sealing compound
36.   Remove lower part of oil pan
•   Apply a bead of silicone sealant (grey) to the sealing surfaces of the lower part of the oil pan
•   Tighten 15x bolt 9.8 Nm
37.   Lower vehicle by its full height
38.   Install cylinder head

Piston Rings, Replace > < Check crankshaft bearing clearance (with micrometer gauge internal measuring device)