vauxhall Workshop Repair Guides

Vauxhall Workshop Service and Repair Manuals

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Replace one piston and/or con-rod > < Crankshaft drive, cylinder block

Corsa D

All Pistons with Con-rod, Remove and Install

  Remove

1.   Remove cylinder head
2.   Detach oil baffle plate
3.   Set crankshaft to TDC of combustion stroke of cylinder 2
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
4.   Remove con-rod bearing caps (1), cylinders 2 and 3
Note:   Note marking (2) on the intake side of the con-rod and con-rod bearing cap. Set aside in the order removed!
•   Unscrew 4x bolts
•   Push 2x piston with con-rod upwards
Object Number: 8063938 Size: DEFAULT


5.   Lower vehicle by its full height
6.   Remove 2x piston
7.   Raise vehicle by its full height
8.   Turn crankshaft 180°
9.   Remove con-rod bearing caps, cylinders 1 and 4
Note:   Note marking on the intake side of the con-rod and con-rod bearing cap. Set aside in the order removed!
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
10.   Lower vehicle by its full height
11.   Remove 2x piston
12.   Take off 8x con-rod bearing shell
Note:   Note removal sequence!
13.   Visually check components
•   Crank drive

  Install

Important:   Align con-rod bearing shell centrally in the con-rod and con-rod bearing cap.
14.   Insert 8x con-rod bearing shell (1)
•   In con-rod and con-rod bearing cap (2)
Note:   Insert con-rod bearing shell with oil bore (3) in con-rod bearing cap.
Object Number: 8063944 Size: DEFAULT


15.   Set piston ring gap
Note:   Displace piston ring gap by 120° .
Object Number: 2417270 Size: DEFAULT


Important:   Arrow (2) on piston head points to engine timing side
16.   Remove pistons of cylinders 1 and 4
•   Coat 2x pistons and cylinder bores with engine oil
•   Push 2x piston rings together with piston tightening strap
•   Insert 2x pistons in cylinder
17.   Raise vehicle by its full height
Important:   Observe correct allocation and installation position (1)
18.   Attach con-rod bearing cap to cylinder 1 and 4
•   Use new bolts
•   Wet 2x con-rod bearing journal with engine oil
•   Tighten 4x new bolt 20 Nm + 40 °
Object Number: 8063939 Size: DEFAULT


19.   Turn crankshaft 180°
20.   Lower vehicle by its full height
21.   Remove pistons of cylinders 2 and 3
22.   Attach oil baffle plate
23.   Install cylinder head

Replace one piston and/or con-rod > < Crankshaft drive, cylinder block