Piston and Connecting Rods Assembly Replace Opel Antara I

Pistons And Connecting Rods Assembly

Remove

1. Remove the engine assembly. For MY 2007, refer to Engine Assembly Replace . From MY 2008, refer to Engine Assembly Replace .
2. Remove both cylinder head assemblies. Refer to Cylinder Head Assembly Replace .
3. Remove the oil pan assembly. Refer to Oil Pan Assembly Replace .
4. Mark the top of the piston being removed to identify its specific bore.
5. Install Tool No. EN-46111 (1) onto the crankshaft (2).
6. Rotate the crankshaft until the piston being removed is at the bottom of its stroke; bottom dead centre (BDC).

Important: If the connecting rod bearings have been used in a running engine, they must be replaced with new connecting rod bearings for reassembly.

7. Before removing the connecting rods, check the connecting rod side clearance using the following procedure:

A. Tap the connecting rod to one end of the crankshaft journal with a dead blow or wooden hammer.

B. Using feeler gauges, measure the clearance between the crankshaft counterweight and the connecting rod.

C. The connecting rod side clearance should not exceed specifications.

D. If the endplay exceeds the specified limits, measure the width of the crankpin end of the connecting rod.

E. If the connecting rod width is significantly smaller than specified and severe wear is present on the side of the connecting rod, replace the connecting rod.

F. If the connecting rod width is within specification and excessive scoring is present on the crankshaft journals, replace the crankshaft.

Important: Do not use a stamp, punch or any other method that may distort or stress the connecting rod and cap. Extensive engine damage may result from a connecting rod that is distorted or stressed.

8. Mark the cylinder number on the connecting rod and the connecting rod cap with a paint stick or permanent marker.

Important: Powdered metal connecting rods have rod bolts which yield when tightened to the specified torque. If the bolts are loosened or removed they must be replaced. Rod bolts that are not replaced will not torque to the correct clamp load and can lead to serious engine damage.

9. Remove the connecting rod bolts (1), loosening progressively from side to side.

Important: The connecting rod caps must remain with the original connecting rod.

10. Remove the connecting rod cap (2).

11. Install connecting rod guide pin set, Tool No. EN-46121 (1) to the connecting rod bolt holes.

Note: Do not damage the crankshaft journal, cylinder wall and piston cooling jets when removing the connecting rod and piston assembly.

12. Using connecting rod guide pin set, Tool No. EN-46121 (1), push the connecting rod and piston assembly (2) through the top of the cylinder.

Important: When dismantled, ensure the connecting rod, connecting rod cap, piston and bearings are organized in their original position and location. This will also aid engine mechanical diagnosis.

13. Remove connecting rod guide pin set, Tool No. EN-46121 (1) from the connecting rod bolt holes.
14. Remove the upper connecting rod bearing from the connecting rod (2).

15. Remove the lower connecting rod bearing (1) from the connecting rod cap (2).

16. Reattach the connecting rod cap (1) to the connecting rod (2) to prevent damage to their mating surfaces.

Note: The cap and rod are a matched set and must be kept together.

17. Repeat steps 4 to 16 for the remaining piston and connecting rod assemblies.

Disassemble

Important: A piston ring expander must be used to remove and install the piston rings. Only expand the rings far enough to fit over the piston lands. If the rings are overexpanded, the top ring will shatter and the others will distort.

1. Remove the piston rings (2) using a piston ring expander (1). Place each ring in a clean shop towel for storage.

Important: Do not reuse the piston pin retainers.

2. Remove the piston pin retainers by using the removal access notch (1) in the side of the piston. Discard the piston pin retainers.

3. Slide the piston pin (1) out of the piston (2). The piston will disconnect from the connecting rod.

Inspect

1. Inspect the pistons for the following conditions.

o Eroded areas at the top of the piston (1).

o Piston pin retainer grooves for burrs (2).

o Worn piston pin bores or worn piston pins (3).

o Scuffed or damaged skirt coating (4).

o Ring grooves for cracks, nicks or burrs that may cause binding (5), and

o Warped or worn ring lands

o Replace pistons that show any signs of damage or excessive wear.

2. Inspect the connecting rods for the following conditions.

• Inspect the piston pin bushing (4) for scoring or damage.
• Inspect the connecting rod beam (1) for twisting or bending.
• Inspect the rod cap (2) for any nicks or damage caused by possible interference.
• Inspect for scratches or abrasion on the rod bearing seating surface.
• If the connecting rod bores contain minor scratches or abrasions, clean the bores in a circular direction with a light emery paper.
• Retain the original bolts (3) for preliminary assembly. They must be replaced for final assembly.

3. Inspect the engine block deck surface for flatness using a straight edge and a feeler gauge. Refer to Engine Specifications .
4. Inspect the bearing bore for concentricity and alignment using cylinder bore check gauge J-8087. Refer to Engine Specifications . If the bearing bore is beyond the specifications, replace the engine block.
5. Inspect the engine block cylinder bore for wear, runout, ridging and taper using a bore gauge. Refer to Engine Specifications .
6. Inspect the engine block cylinder bore for glazing. Lightly hone the cylinder bore as necessary. Measure

1. Measure the piston width using the following procedure.

• Using an outside micrometer, measure the width of the piston at the thrust surfaces of the piston, perpendicular to the piston pin centreline.
• Compare the measurement of the piston to its original cylinder by subtracting the piston width from the cylinder diameter.
• If the clearance obtained through measurement is greater than the provided specifications and the cylinder bores are within specification, replace the piston.

2. Measure the piston pin bore to piston pin (2) clearances using the following procedure.

• Piston pin bores and pins must be free of varnish or scuffing.
• Use an outside micrometer (1) to measure the piston pin in the piston contact areas.

• Using an inside micrometer, measure the piston pin bore (1). Compare the result with the piston pin diameter and piston pin to piston pin bore clearance. Refer to Engine Specifications .
• If the clearance is excessive, determine which piece is out of specification and replace as required.
• Replace the piston if any of its dimensions are out of specification.
• If the new piston does not meet clearance specifications, the cylinder block may need to be oversized to 0.25 . There is only one size of oversized pistons and rings available for service.

3. Measure the piston ring end gap using the following procedure.

• Piston pin bores and pins must be free of varnish or scuffing.
• Place the piston ring (1) in the area of the bore where the piston ring will travel, approximately 25 mm below the deck surface. Ensure the ring is square with the cylinder bore by positioning the ring with the piston head.
• Measure the end gap of the piston ring with feeler gauges (2).
• If the clearance exceeds the provided specifications, the piston rings must be replaced.
• Repeat the procedure for all piston rings.

4. Measure the piston ring side clearance using the following procedure.

• Roll the piston ring entirely around the piston ring groove. If any binding is caused by the ring groove, dress the groove with a fine file. If any binding is caused by a distorted piston ring, replace the ring.
• With the piston ring on the piston, use feeler gauges to check clearance at multiple locations.
• Compare the measurements with piston ring side clearance. Refer to Engine Specifications .
• If the clearance is greater than specifications, replace the piston rings.
• If the new ring does not reduce the clearance to the correct specification, install a new piston.

If the new piston does not meet clearance specifications, the cylinder block may need to be oversized to 0.25 mm. There is only one size of oversized pistons and rings available for service.

5. Measure the connecting rod piston pin bore to piston pin clearance using the following procedures.

• Using an outside micrometer (1), take two measurements of the piston pin (2) in the area of the connecting rod contact.

• Using an inside micrometer, measure the connecting rod piston pin bore (1).
• Subtract the piston pin diameter from the piston pin bore.
• Compare the clearance measurements. Refer to Engine Specifications .
• If the clearance is excessive, replace the piston pin. If a new pin does not resolve the clearance problem, replace the connecting rod.

7. Measure the connecting rod crankshaft bearing bore (1) using the following procedures.

• Using an inside micrometer, measure the connecting rod crankshaft bearing bore.
• Compare the bore measurements. Refer to Engine Specifications .

8. Replace the connecting rod if the bore is out of specification. Do not recondition the connecting rod.

Assemble

Note: The arrow located on top of the piston must point toward the front of the engine.

Note: The connecting rod is non-directional and may be assembled/reassembled to the piston in either direction.

1. Lubricate the piston pin (1) bores in the piston (2) and the connecting rod with clean engine oil.
2. Assemble the piston and piston pin to the connecting rod. Correctly orientate the piston when reusing a marked connecting rod.
3. Align the piston pin bore with the connecting rod pin bore.
4. Slide the piston pin into the piston and the connecting rod.

Important: New piston pin retainers must be used. Never reuse the piston pin retainers.

5. Install new piston pin retainers (1).
6. Ensure the piston pin retainers are fully seated in their grooves.
7. Repeat steps 1 to 6 for the remaining pistons.

8. Correctly orient the oil control ring expander (1) before installation. The ends of the expander must be facing toward the top of the piston.

9. Using a piston ring expander, install the oil control ring assembly using the following procedure:

a. Install the expander ring (3).

b. Install the two oil scraper rings (4). Expand the rings only enough to clear the piston diameter. Over-expanding the piston rings will distort or crack the rings.

10. Install the second (2) and top (1) piston rings as follows.

11. Using the ring expander (1), install the second (2) piston ring (2) onto the piston (3). Do not over-expand the ring. Repeat for the top ring.

12. Once the rings are installed, set the ring gaps for the oil control, second and top ring as follows. Use the piston location arrow for reference.

• Lower oil control ring position (1).
• Upper oil control ring position (2).
• Top ring position (3).
• Oil control ring expander position (4).
• Second ring position (5).

Important: If the connecting rod bearings have been used in a running engine, they must be replaced with new connecting rod bearings for reassembly.

13. Clean the connecting rod (2) and the connecting rod cap bearing bore with a lint-free cloth.
14. Clean the oil from behind the connecting rod bearing halves.
15. Install a new upper connecting rod bearing (1) into position. Roll the bearing into position so the lock tang engages the alignment slot. The bearing must fit flush in the connecting rod.

16. Install the lower connecting rod bearing (1) into position in the connecting rod cap (2).
17. Roll the bearing into position so the lock tang engages the alignment slot. The bearing must fit flush with the connecting rod cap.

Install

1. Liberally lubricate the cylinder walls, piston rings and piston skirts with engine oil.

Important: The piston is directional and must be installed in the engine block in the correct direction. The locating arrow on the top of each piston must be pointing toward the front of the engine.

2. Select the correctly numbered piston/connecting rod assembly for the cylinder. A dot (1) showing correct piston orientation is located on the top of the piston.

3. Install connecting rod guide pin set, Tool No. EN-46121 (1) into the connecting rod bolt holes.

4. Compress the piston rings using a commercially available ring compressor.

Important: Extreme care must be used when installing the piston and connecting rod to ensure the rod does not scrape or nick the cylinder bore, oil jets, or crankshaft surfaces.

5. Using both hands from the top and bottom of the cylinder, slowly guide the piston (2) and connecting rod assembly into the cylinder. Do not allow the connecting rod to contact the cylinder wall.
6. When the ring compressor contacts the deck surface, gently tap the piston into the cylinder using the handle end of a dead-blow hammer. Guide the connecting rod onto the crankshaft bearing journal using connecting rod guide pin set, Tool No. EN-46121 (1) while gently tapping the piston into the cylinder with a soft-blow hammer.

7. Remove connecting rod guide pin set, Tool No. EN-46121 (1) from the connecting rod bolt holes.

8. Carefully guide the connecting rod away from the crankshaft connecting rod journal slightly to lubricate the crankshaft connecting rod bearing journal.
9. Apply a liberal amount of clean engine oil to the crankshaft connecting rod bearing journal.
10. Guide the connecting rod to the crankshaft connecting rod journal.
11. Install the connecting rod end cap (1) on its original connecting rod and ensure the bearing lock tangs are aligned on the same side of the rod.

Important:

o Do not lubricate the new connecting rod bolts. The new bolts have a pre-applied graphite lubricant. Applying lubricant to the connecting rod bolts will effect the clamp load when the connecting rod bolts are tightened to the specified torque. Incorrect clamp load can lead to component failure and extensive engine damage.

o Do not reuse the old connecting rod bolts.

12. Install new connecting rod bolts into the connecting rod cap.

Tighten

Tighten the connecting rod cap bolts to 30 N•m (22 lb-ft) and loosen the bolts completely. Tighten the connecting rod cap bolts to 25 N•m (18 lb-ft) again, and turn the bolts another 110° using the angular torque gauge KM-470-B.

Note: During and after installation, ensure each piston is positioned correctly in the correct cylinder. The locating arrow on the top of each piston must be pointing toward the front of the engine.

13. Repeat these procedures for the remaining piston/connecting rod assemblies.
14. Reinstall the oil pan and oil pump pick up assembly. Refer to Oil Pan Assembly Replace .
15. Reinstall the cylinder heads. Refer to Cylinder Head Assembly Replace .
16. Reinstall the engine assembly. For MY 2007, refer to Engine Assembly Replace . From MY 2008, refer to Engine Assembly Replace .