vauxhall Workshop Repair Guides

Vauxhall Workshop Service and Repair Manuals

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Piston Rings, Replace > < Check crankshaft bearing clearance (with plastigage)

Corsa D

All Pistons with Con-Rods, Remove and Install

  Remove

1.   Remove cylinder head
2.   Drain engine oil
•   Place collecting basin underneath.
•   Unscrew drain bolt
3.   Detach wiring harness plug from dynamic oil level check sensor
4.   Remove oil pan
•   from transmission
– Unscrew 3x bolts (2)
•   From cylinder block
– Unscrew 16x bolts (1)
Object Number: 3446280 Size: DEFAULT


5.   Remove KM-952
6.   Detach con-rod bearing caps (1) from cylinder 2 and 3
Note:   The mating surfaces of the con-rods and con-rod bearing caps form an individual fit and should never be swapped over or damaged. To avoid damage, do not put the con-rods and con-rod bearing caps down on the mating surfaces.
•   Mark order of con-rod bearing caps
•   Unscrew 4x bolts
•   Take out 4x con-rod bearing caps
Note:   Note installation position, bead (arrow) on the con-rod bearing cap points towards the transmission side.
•   Push piston with con-rod upwards
Object Number: 2410514 Size: DEFAULT


7.   Lower vehicle by its full height
8.   Take 2x piston with con-rod out of cylinder block
9.   Turn crankshaft
•   Pull timing chain upwards
•   Turn crankshaft 180°
10.   Raise vehicle by its full height
11.   Detach con-rod bearing caps (1) from cylinder 1 and 4
Note:   The mating surfaces of the con-rods and con-rod bearing caps form an individual fit and should never be swapped over or damaged. To avoid damage, do not put the con-rods and con-rod bearing caps down on the mating surfaces.
•   Mark order of con-rod bearing caps
•   Unscrew 4x bolts
•   Take out 4x con-rod bearing caps
Note:   Note installation position, bead (arrow) on the con-rod bearing cap points towards the transmission side.
•   Push piston with con-rod upwards
Object Number: 2410511 Size: DEFAULT


12.   Lower vehicle by its full height
13.   Take 2x piston with con-rod out of cylinder block

  Install

14.   Clean and check all the components, replace if necessary
Note:   Pistons may only be replaced in conjunction with con-rod and piston pin.
15.   Set piston ring gap
•   First piston ring (right-hand ring) in position (1)
•   Second piston ring (minute ring) in position (4)
•   Interim ring of oil scraper ring in position (5), steel band rings of oil scraper ring in position (2) and/or (3)
Object Number: 2417766 Size: DEFAULT


16.   Install piston of cylinder 1 and 4
Note:   Arrow (1) on the piston head points to engine timing side – bead (2) on the con-rod points to transmission side.
•   Coat pistons and cylinder bores with engine oil
•   Push piston rings together with piston tightening strap
•   Carefully push piston into cylinder bore with hammer shaft until con-rod sits on the con-rod bearing journal of the crankshaft
Object Number: 2399440 Size: DEFAULT


17.   Raise vehicle by its full height
18.   Install con-rod bearing cap
Note:   Bead on con-rod bearing cover points towards gearbox side.
•   Wet con-rod bearing journal with engine oil
•   Use new bolts
Important:   Only use bolts of size M6.5.
•   Tighten bolt
– Tightening torque 13 Nm + 60° + 15°
19.   Lower vehicle by its full height
20.   Turn crankshaft
•   Pull timing chain upwards
•   Turn crankshaft 180°
21.   Install piston of cylinder 2 and 3
Note:   Arrow on the piston head points to engine timing side. Bead on the con-rod points to transmission side.
•   Coat pistons and cylinder bores with engine oil
•   Push piston rings together with piston tightening strap
•   Carefully push piston into cylinder bore with hammer shaft until con-rod sits on the con-rod bearing journal of the crankshaft
22.   Raise vehicle by its full height
23.   Install con-rod bearing cap
Note:   Bead on con-rod bearing cover points towards gearbox side.
•   Wet con-rod bearing journal with engine oil
•   Use new bolts
Important:   Only use bolts of size M6.5.
•   Tighten bolt
– Tightening torque 13 Nm + 60° + 15°
24.   Screw 2x centring pin into engine block using EN-49980
Note:   Screw centring pin diagonally into engine block, hand-tight.
25.   Install oil pan
•   Apply sealant
•   Complete assembly work within 10 minutes
•   Screw in 19x bolts
•   Unscrew 2x centring pin from engine block using EN-49980
•   Tighten 3x bolt on transmission
– Tightening torque 40 Nm .
•   Tighten 16x bolt from cylinder block
– Tightening torque 10 Nm .
26.   Screw oil drain bolt into oil pan
•   Use new seal ring
•   Tighten oil drain bolt
– Tightening torque 14 Nm .
27.   Detach wiring harness plug from dynamic oil level check sensor
28.   Install cylinder head
29.   Charge with specified volume of engine oil.
•   Start engine and allow to run until oil pressure control indicator goes off
•   Check engine oil level, correct if necessary

Piston Rings, Replace > < Check crankshaft bearing clearance (with plastigage)