Cylinder Block Replace Opel Antara I



Cylinder Block Replace

Disassemble

1. Remove oil jet bolt (1) attaching the oil jet (2), three places.

2. Remove the cylinder block-to-oil pan alignment dowels (1) and the bank 1 side front oil pan rail oil gallery expansion plug (2).

3. Remove the bank 1 side oil gallery threaded plug (1) and coolant drain threaded plug (2).

4. Remove the rear oil gallery threaded plug (1), the bank 2 side coolant drain threaded plug (2) and the left-hand side oil gallery threaded plug (3).

Important: Do not force coolant expansion plugs downwards during removal procedure as the cylinder block will be damaged.

5. Remove the coolant expansion plugs (1) and the cylinder block-to-cylinder head alignment dowels (2).

6. Remove the cylinder block-to-transmission alignment dowels (1).

Remove the front oil gallery expansion plug (1). Clean

1. Remove all thread sealant, gasket material or sealant using a commercially available plastic or wood scraper.
2. Clean all the following areas with a suitable solvent:
3. Clean all threaded and through holes with a suitable solvent.
4. Dry the engine block with compressed air.

Measure

Measuring Cylinder Bore Diameter

1. Measure the cylinder bore diameter 37 mm from the deck face (1) using a commercially available bore gauge or Tool No. J-8087 (2).
2. Record the results and compare with the dimensions listed in the specifications.

Note: If the cylinder diameter exceeds the specifications, the cylinder block may be oversized to 0.25 mm. Only one size of oversized pistons and rings are available for service. If the cylinder bore diameter exceeds specification by more than 0.25 mm, the cylinder block must be replaced.

Measuring Cylinder Bore Taper

1. Measure the cylinder bore along the thrust surfaces, perpendicular to the crankshaft centreline, at 10 mm below the deck surface and record the measurement.
2. Measure the cylinder bore along the thrust surfaces, perpendicular to the crankshaft centreline, at 100 mm below the deck surface and record the measurement.
3. Calculate the difference between the two measurements. The result will be the cylinder taper.
4. Compare the results with the dimensions listed in the specifications.
5. If the cylinder diameter exceeds the specifications, the cylinder block may be oversized to 0.25 mm. Only one size of oversized pistons and rings are available for service. If the cylinder bore diameter exceeds specification by more than 0.25 mm, the cylinder block must be replaced.

Measuring Cylinder Bore Out-of-Round

1. Measure both the thrust and non-thrust cylinder diameter at 10 mm below the deck. Record your measurements.
2. Calculate the difference between the two measurements. The result will indicate out-of-round at the upper end of the cylinder.
3. Measure both the thrust and non-thrust cylinder diameter at 100 mm below the deck surface. Record your measurements.
4. Calculate the difference between the two measurements. The result will indicate out-of-round at the lower end of the cylinder.
5. Compare your results with the dimensions listed in the specifications.
6. If the cylinder diameter exceeds the specifications, the cylinder block may be oversized to 0.25 mm. Only one size of oversized pistons and rings are available for service. If the cylinder bore diameter exceeds specification by more than 0.25 mm, the cylinder block must be replaced.

Assemble

1. Place RTV sealant on new coolant expansion plugs (1) and install the new coolant expansion plugs.
2. Install the cylinder block-to-cylinder head alignment dowels (2).

3. Install a new front oil gallery expansion plug (1).

4. Install the cylinder block-to-transmission alignment dowels (1).

5. Install the rear oil gallery threaded plug (1), bank 2 side coolant drain threaded plug (2) and the left-hand side oil gallery threaded plug (3).

Tighten

Tighten the cylinder block rear oil gallery threaded plug to 31 N•m (23 lb-ft).

Tighten the bank 2 side coolant drain threaded plug to 31 N•m (23 lb-ft).

Tighten the bank 2 side oil gallery threaded plug to 31 N•m (23 lb-ft).

6. Install the oil gallery threaded plug (1) and the right-hand side coolant drain threaded plug (2).

Tighten

Tighten the bank 1 side oil gallery threaded plug to 31 N•m (23 lb-ft).

Tighten the bank 1 side coolant drain threaded plug to 31 N•m (23 lb-ft).

7. Install the new bank 1 side front oil pan rail oil gallery expansion plug (1) and the cylinder block-to-oil pan alignment dowels (2).

8. Install the oil jet (2), three places.
9. Install the oil jet attaching bolt (1), three places.

Tighten

Tighten the oil jet attaching bolt to 10 N•m (89 lb-in).