Replace One Piston And/or Con-Rod Opel Agila A

Remove

1. 1. Remove piston with con-rod

Important. Do not damage piston and con-rod. Use protective jaws

2. 2. Detach piston from con-rod • Clamp piston (1) with con-rod (3) in vice • Remove 2 piston pin retaining rings (2) • Remove piston pin (4) – Slide piston pin off of piston and con-rod by hand • Remove piston

Install

Important. Note installation position. Only install the piston on the con-rod so that the etched number in the con-rod (1) is opposite the oil spray nozzle indentation in the piston (2)

3. 3. Install piston on con-rod • Insert piston pin in piston • Place piston with piston pin on con-rod • Insert piston pin through con-rod eye in piston

Note. Coat piston pin with engine oil

Note. The grooves for the piston pin retaining rings must be free.

4. 4. Insert 2 piston bolt retaining rings in the piston

Note. Ring gap must be positioned near measurement one (maximum 30° )

Important. Maximum ring gap spread must not exceed measurement I ( 28 mm )

5. 5. Install piston rings • Insert 3 piston rings in ring grooves using piston ring pliers (1)

Note. Note marking on piston rings

6. 6. Adjust piston ring gaps

Note. Position piston ring gaps so they are offset 120° .

7. 7. Remove piston with con-rod from vice
8. 8. Install piston with con-rod