Vauxhall Workshop Service and Repair Manuals

Mark order of con-rod bearing caps – bead (1) of con-rod bearing caps points to transmission side. Remove con-rod bearing cap from con-rod. The mating surfaces of the cod-rods and the con-rod bearing caps form an individual fit and as a result must not be damaged or replaced under any circumstances. To avoid damage, do not lay con-rods and con-rod bearing caps on mating surfaces.

Remove crankshaft bearing cover – mark installation position. Remove crankshaft from cylinder block.

Caution

Note crankshaft pulse pickup sensor disc when removing and laying aside the crankshaft. Deformation of the sensor disc negatively affects the engine.

When replacing crankshaft – remove crankshaft pulse pickup sensor disc.

  Clean

Clean all parts. Check crankshaft – see operation "Crankshaft, Check".

  Install

When replacing crankshaft – attach crankshaft pulse pick-up sensor disc with new bolts to crankshaft – tightening torque 15 Nm / 11 lbf. ft.

Coat bearing shells with engine oil. Insert new bearing shells in cylinder block and bearing cap. Insert crankshaft in cylinder block.

The seating of the crankshaft can be corrected by light blows on the crank webs with a rubber hammer.

Apply bead of adhesive sealing compound (black) to grooves of the rear crankshaft.

Install crankshaft and con-rod bearing caps.

Caution

Note marks and installation position.

Torque/angle method

Crankshaft bearing cap to cylinder block – 50 Nm + 60° + 15° 1) 2) . Con-rod bearing cap to con-rod – 35 Nm + 45° + 15° 1)   .

  Install

Lightly coat sealing lip of new seal ring with silicon grease (white) and press over Protective Ring KM-635-1.

Drive seal ring into cylinder block with KM-635-2 (1) and KM-535 (2).

  Clean

Clean contact surfaces of crankshaft and flywheel or drive disc.