Pistons and Connecting Rods Replace Opel Antara I



Pistons and Connecting Rods Replace

Tools Required

J-8037 Universal Piston Ring Compressor

J-8087 Cylinder Bore Check Gauge

KM-427 Piston Pin Service Set

KM-470-B Angular Torque Gauge

Remove

1. Remove the cylinder head with the intake manifold and exhaust manifold attached. Refer to Cylinder Head and Gasket Replace .
2. Remove the oil pan. Refer to Oil Pan Replace .
3. Remove the oil suction pipe and the O-ring.

4. Remove the oil pan scraper.

5. Remove the crankshaft balancer unit assembly. Refer to Crankshaft Balancer Unit Assembly Replace .

6. Position the piston to the bottom of the piston stroke.
7. Mark the connecting rod cap for position.
8. Remove the connecting rod cap bolts.
9. Remove the connecting rod cap and the lower connecting rod bearing.
10. Remove the upper connecting rod bearing.

Warning: Use care when handling the piston. Worn piston rings are sharp and may cause injury.

11. Remove the piston.
12. Expand the piston rings by using the universal piston ring compressor J-8037.
13. Remove the piston rings.

14. Remove the piston pin from the piston and connecting rod assembly using the piston pin service set KM-427.
15. Separate the piston from the connecting rod.

Inspect

1. Inspect the pistons for the following conditions.
2. Replace pistons that show any signs of damage or excessive wear.

3. Measure the piston width using the following procedure.

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

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

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

7. Inspect the connecting rods for the following conditions.

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

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

10. Inspect the engine block deck surface for flatness using a straight edge and a feeler gauge. Refer to Engine Specifications .
11. 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.
12. Inspect the engine block cylinder bore for wear, runout, ridging and taper using a bore gauge. Refer to Engine Specifications .
13. Inspect the engine block cylinder bore for glazing. Lightly hone the cylinder bore as necessary.

Install

Note: For ease of installation of the piston pin, the connecting rod should be heated to 280°C. Heat the upper connecting rod only. Use commercial thermo color material to determine the correct temperature. When the thermo color material changes from black to green the temperature is correct for installation.

1. Align the notch on the piston and connecting rod so that the proper sides will be facing the front of the engine.
2. Install the piston pin guide through the piston and the connecting rod.
3. Coat the piston pin with clean oil.
4. Install the piston pin into the opposite side of the piston.
5. Install the piston pin into the piston and connecting rod assembly using the piston pin service set KM-427.

6. Select a set of new piston rings.
7. Install the piston oil ring, the expander then the second piston oil ring to the bottom ring groove of the piston.
8. Install the second compression ring to the middle ring groove of the piston.
9. Install the top compression ring to the top ring groove of the piston.

10. Use the piston ring expander to install the piston rings. Do not expand the piston rings beyond the expansion necessary for installation.
11. Stagger the piston oil rings, the oil ring rail gaps, the second compression ring and the top compression ring in relation to the notch on the top of the piston.

12. Lubricate the cylinder wall and the piston rings with clean engine oil.
13. Install the piston using the universal piston ring compressor J-8037 and a wooden handle. Guide the lower connecting rod end to prevent damaging the crankshaft journal.
14. Install the connecting rod cap and bearings. For crankshaft bearings refer to Crankshaft Bearings - Gauging Plastic . For connecting rod bearings refer to Connecting Rod Bearings - Gauging Plastic .

15. Install the connecting rod cap bolts.

Tighten

Tighten the connecting rod bearing cap bolts to 35 N•m (26 lb-ft). Using the angular torque gauge KM-470-B, tighten the bolts one turn of 45 degrees plus on turn of 15 degrees.

16. Install the crankshaft balancer unit assembly.

Tighten

Tighten the crankshaft balancer unit assembly bolts to 20 N•m (15 lb-ft) and turn the bolts another 45° using the angular torque gauge KM-470-B.

17. Install the oil pan scraper bolts.

Tighten

Tighten the oil pan scraper bolts to 8 N•m (71 lb-in.).

18. Install the oil suction pipe with the new O-ring.

Tighten

Tighten the oil suction pipe bolts to 8 N•m (71 lb-in.).

19. Install the oil pan. Refer to Oil Pan Replace .
20. Install the cylinder head with the intake manifold and exhaust manifold attached. Refer to Cylinder Head and Gasket Replace .