vauxhall Workshop Repair Guides

Vauxhall Workshop Service and Repair Manuals

ABOUT US
Replace one piston and/or con-rod (piston removed with con-rod) > < Piston, Replace

Astra H

All Pistons with Con-rod, Remove and Install

Spezialwerkzeugliste:
  • KM-J-41742

  Remove

1.   Remove oil pan
2.   Remove cylinder head
3.   Raise vehicle by its full height
4.   Mark con-rod bearing cap (1)
Object Number: 2417756 Size: DEFAULT


5.   Loosen con-rod bearing cap
•   Per cylinder
– Unscrew 2x bolts
•   Remove con-rod bearing cap
Object Number: 2417755 Size: DEFAULT


6.   Push con-rod upwards
Note:   Take care to ensure that the con-rod does not damage the liner when being removed. Rotate crankshaft if necessary
•   Push con-rod upwards until piston protrudes above cylinder block
Object Number: 2417757 Size: DEFAULT


7.   Lower vehicle by its full height
8.   Remove con-rod
•   Remove with piston
9.   Remove con-rod bearing shells (1 and 2)
•   Identify con-rod bearing shells
Note:   Observe the correct sequence
10.   Visually check components
•   Crank drive
Object Number: 2417760 Size: DEFAULT


  Install

11.   Insert con-rod bearing shells (1 and 2)
•   In con-rod, con-rod bearing cap
– Coat with engine oil
Object Number: 2417760 Size: DEFAULT


12.   Insert piston cylinder 1
•   Screw in KM-J-41742 (1)
– To con-rod
•   Adjust piston rings
– Ring gap distribution 120°
– Rotate upper oil scraper ring gap 25 - 50 mm left, and rotate lower oil scraper ring gap 25 - 50 mm right facing the intermediate ring gap
•   Push piston rings together with piston tightening strap
•   Push in piston
13.   Insert piston cylinder 2
14.   Insert piston cylinder 3
15.   Insert piston cylinder 4
Object Number: 2417768 Size: DEFAULT


16.   Raise vehicle by its full height
17.   Install con-rod bearing cap
•   Insert 4x con-rod bearing cap
•   Use new bolts
•   Screw in 8x bolts
•   Tighten bolts 25 Nm + 100° + 25°
18.   Lower vehicle by its full height
19.   Install cylinder head
20.   Install oil pan

Replace one piston and/or con-rod (piston removed with con-rod) > < Piston, Replace