Vauxhall Workshop Service and Repair Manuals

All pistons with con-rod, remove and install - Diesel engine

  Remove

1.	Remove upper part of oil pan

2.   Remove oil intake pipe (2) •   Unscrew bolt 3.   Remove oil baffle plate (1). •   Unscrew 5x bolts

Warning:   Important: The fracture surfaces of the con-rods and the con-rod bearing caps build an individual fit and must not at any time be confused or damaged. To prevent damage, do not not place the con-rods or con-rod bearing caps on the fracture surfaces. 7.   Remove 2x con-rod bearing cap (1) •   Cylinder 2 and cylinder 3 – Unscrew 4x nut •   Remove 2x con-rod bearing caps Note:   Note identification mark on con-rod bearing cap and con-rod. Apply identification mark if not present •   Push 2x pistons upwards

Warning:   Important: The fracture surfaces of the con-rods and the con-rod bearing caps build an individual fit and must not at any time be confused or damaged. To prevent damage, do not not place the con-rods or con-rod bearing caps on the fracture surfaces. 9.   Remove 2x con-rod bearing cap (1) •   Cylinder 1 and cylinder 4 – Unscrew 4x nut •   Remove 2x con-rod bearing caps Note:   Note identification mark on con-rod bearing cap and con-rod. Apply identification mark if not present •   Push 2x pistons upwards

13.   Remove 12x piston ring with piston ring pliers (1) Note:   Observe correct assignment •   Remove spiral-type expander of the oil scraper ring out of piston ring groove

  Measure

14.   Measure 3x ring gaps •   Insert 3x new piston ring in cylinder •   Measure joint clearance with feeler gauge – Permissible ring gap

15.   Measure vertical play •   Insert piston rings into piston ring groove Note:   Note markings (arrow) on the compression rings ("T", "2T" point upwards) – 1st compression ring (T) – 2nd compression ring (2T) – Oil scraper ring •   Measure vertical play with feeler gauge – Permissible vertical play

  Install

16.   Install 12x piston ring with piston ring pliers Note:   Observe correct assignment •   Insert spiral-type expander of oil scraper ring in piston ring groove •   Install oil scraper ring •   Install compression rings Note:   Note markings on the compression rings – 1st compression ring (T) – 2nd compression ring (2T)

17.   Set piston ring gap •   Arrange joints of piston rings offset by 90° – 1st compression ring (I) – 2nd compression ring (II) – Oil scraper ring (III) – Spiral-type expander (IV)

19.   Install 2x piston Important:   Marking (1) on piston head and marking (2) on con-rod point towards the engine timing side. •   Cylinder 1 and cylinder 4 Note:   Coat with engine oil •   Force piston rings together with piston ring tensioning belt Note:   Coat with engine oil •   Push in 2x pistons

21.   Attach 2x con-rod bearing cap Important:   Note cylinder sequence marking on con-rod bearing cap and con-rod. Narrow bead (arrow) points towards engine timing side •   Tighten 4x new nuts 25 Nm + 100° + 15°

24.   Install 2x piston Important:   Marking (1) on piston head and marking (2) on con-rod point towards the engine timing side •   Cylinder 2 and cylinder 3 Note:   Coat with engine oil •   Force piston rings together with piston ring tensioning belt Note:   Coat with engine oil •   Push in 2x pistons

26.   Attach 2x con-rod bearing cap Important:   Note cylinder sequence marking on con-rod bearing cap and con-rod. Narrow bead (arrow) points towards engine timing side. •   Tighten 4x new nuts 25 Nm + 100° + 15°

32.	Install upper part of oil pan