Connecting Rod Shell Bearings Replacement Opel Agila B

Remove

1. 1. Remove oil level dipstick
2. 2. Raise vehicle

Important. Observe the relevant environmental regulations when disposing of used engine oil.

3. 3. Drain engine oil • Place collecting container below • Remove drain plug • Remove sealing washer
4. 4. Install drain plug 20 Nm to oil pan • Install new sealing washer • Remove collecting container
5. 5. Disconnect diesel particulate filter (DPF) pressure sensor hose (1) (if installed) from DPF pressure sensor pipe (2) • Release clip

6. 6. Disconnect harness (1) from DPF temperature sensor (if installed) • Release from support bracket, then disconnect harness connector

7. 7. Release exhaust front pipe from exhaust down pipe • Release clamp (1)

8. 8. Release DPF (1) (if installed) from exhaust centre pipe • Remove 2x nut (2) • Remove gasket

9. 9. Remove front exhaust pipe with DPF (2) (if installed) from vehicle • Release from 2x rubber mount (1), then slide out

10. 10. Release catalytic converter bracket (1) from transmission • Remove bolt (2)

11. 11. Remove flywheel shield from bracket (2) • Remove bolt
12. 12. Remove bracket from engine block and transmission • Remove 6x bolt (1)

13. 13. Remove oil pan (2) • Unscrew 13x bolt • Unscrew 2x nut • Disconnect carefully with Seal Breaker KM-J-37228 (1) from cylinder block base plate

14. 14. Remove oil baffle plate (1) from cylinder block • Remove 6x bolt (2)

Important. The mating surfaces of the connecting rods and bearing caps form an individual fit and must not be damaged or interchanged.

15. 15. Position No. 1 piston and No. 4 piston at bottom dead centre • Rotate crankshaft as necessary
16. 16. Remove bearing cap from No. 1 piston connecting rod • Apply match marks to bearing cap and connecting rod • Remove 2x bolt

Note. No. 1 piston is located towards the timing end of engine block.

17. 17. Remove 2x bearing from No. 1 piston connecting rod and bearing cap • Push out

Important. The mating surfaces of the connecting rods and bearing caps form an individual fit and must not be damaged or interchanged.

18. 18. Remove bearing cap from No. 4 piston connecting rod • Apply match marks to bearing cap and connecting rod • Remove 2x bolt
19. 19. Remove 2x bearing from No. 4 piston connecting rod and bearing cap • Push out

Important. The mating surfaces of the connecting rods and bearing caps form an individual fit and must not be damaged or interchanged.

20. 20. Position No. 2 piston and No. 3 piston at bottom dead centre • Rotate crankshaft as necessary
21. 21. Remove bearing cap from No. 2 piston connecting rod • Apply match marks to bearing cap and connecting rod • Remove 2x bolt
22. 22. Remove 2x bearing from No. 2 piston connecting rod and bearing cap • Push out

Important. The mating surfaces of the connecting rods and bearing caps form an individual fit and must not be damaged or interchanged.

23. 23. Remove bearing cap from No. 3 piston connecting rod • Apply match marks to bearing cap and connecting rod • Remove 2x bolt
24. 24. Remove 2x bearing from No. 3 piston connecting rod and bearing cap • Push out

Install

Important. The mating surfaces of the connecting rods and bearing caps form an individual fit and must not be damaged or interchanged.

Important. Ensure markings on cap correspond to markings on connecting rod.

25. 25. Position No. 1 piston and No. 4 piston at bottom dead centre • Rotate crankshaft as necessary
26. 26. Install 2x new bearing to No. 1 piston connecting rod and bearing cap • Push in
27. 27. Install bearing cap to No. 1 piston connecting rod • Apply clean engine oil to bearing cap • Align match marks on bearing cap and connecting rod • Install 2x new bolt 20 Nm + 40° • Use Angle Meter KMJ-8059

Important. The mating surfaces of the connecting rods and bearing caps form an individual fit and must not be damaged or interchanged.

Important. Ensure markings on cap correspond to markings on connecting rod.

28. 28. Install 2x new bearing to No. 4 piston connecting rod and bearing cap • Push in
29. 29. Install bearing cap to No. 4 piston connecting rod • Apply clean engine oil to bearing cap • Align match marks on bearing cap and connecting rod • Install 2x new bolt 20 Nm + 40° • Use Angle Meter KMJ-8059

Important. The mating surfaces of the connecting rods and bearing caps form an individual fit and must not be damaged or interchanged.

Important. Ensure markings on cap correspond to markings on connecting rod.

30. 30. Position No. 2 piston and No. 3 piston at bottom dead centre • Rotate crankshaft as necessary
31. 31. Install 2x new bearing to No. 2 piston connecting rod and bearing cap • Push in
32. 32. Install bearing cap to No. 2 piston connecting rod • Apply clean engine oil to bearing cap • Align match marks on bearing cap and connecting rod • Install 2x new bolt 20 Nm + 40° • Use Angle Meter KMJ-8059

Important. The mating surfaces of the connecting rods and bearing caps form an individual fit and must not be damaged or interchanged.

Important. Ensure markings on cap correspond to markings on connecting rod.

33. 33. Install 2x new bearing to No. 3 piston connecting rod and bearing cap • Push in
34. 34. Install bearing cap to No.3 piston connecting rod • Apply clean engine oil to bearing cap • Align match marks on bearing cap and connecting rod • Install 2x new bolt 20 Nm + 40° • Use Angle Meter KMJ-8059
35. 35. Install oil baffle (1) to cylinder block • Install 6x bolt (2) 9 Nm

36. 36. Clean mating surfaces of cylinder block and oil pan
37. 37. Apply sealant to cylinder block base plate and oil pan – see “Sealants, Adhesives and Lubricants”
38. 38. Install oil pan to cylinder block • Install 13x bolt, 2x nut 9 Nm

39. 39. Install bracket (2) to cylinder block and transmission • Install 6x bolt; do not tighten at this stage • Secure bracket to transmission – Secure 2x bolt 40 Nm • Secure bracket to cylinder block – Secure 4x bolt (1) 30 Nm
40. 40. Install flywheel shield to bracket • Install bolt 40 Nm

41. 41. Secure catalytic converter bracket (1) to transmission • Install bolt (2)

42. 42. Install front exhaust pipe with DPF (2) (if installed) to vehicle • Secure to 2x rubber mount (1)

43. 43. Secure DPF (1) (if installed) to exhaust centre pipe • Install new gasket • Install 2x nut (2) 60 Nm

44. 44. Secure exhaust front pipe to exhaust down pipe • Secure clamp (1) 25 Nm

45. 45. Connect harness (1) to DPF temperature sensor (if installed) • Secure harness to support bracket, then connect harness connector

46. 46. Connect DPF pressure sensor hose (1) to DPF pressure sensor pipe (2) (if installed) • Secure clip

47. 47. Lower vehicle
48. 48. Install oil level dipstick
49. 49. Fill engine with oil to correct level