Replacing One Piston / Con-Rod Opel Astra H

Remove

1. 1. Remove lower engine splash guard
2. 2. Disconnect catalytic converter control oxygen sensor wiring harness plug • Expose wiring harness
3. 3. Remove front exhaust pipe
4. 4. Remove oil drain bolt

Note. Collect engine oil

5. 5. Disconnect wiring harness plug (1) for dynamic oil level control and remove retaining ring (2)
6. 6. Detach lower part of oil pan (3) from upper part of oil pan

7. 7. Clean sealing surfaces and remove gasket remnants.
8. 8. Remove oil filter from oil pump with KM-726-A
9. 9. Detach union nut (4) from turbocharger oil feed line (turbocharger)

Note. Place collecting basin underneath.

10. 10. Detach bracket (3) from cylinder block
11. 11. Detach union nut (1) from cylinder block flange and remove turbocharger oil feed line (cylinder block) (2)

12. 12. Detach oil pan top bolts (1) from transmission housing
13. 13. Detach upper part of oil pan (2) from cylinder block and remove oil pump

14. 14. Detach 2x oil intake pipe bolts (1) from balancer shaft unit

15. 15. Move upper part of oil pan in direction of arrow and detach 2x oil intake pipe bolts (1) from oil pump
16. 16. Remove upper part of oil pan with oil intake pipe

17. 17. Clean sealing surfaces and remove gasket remnants.
18. 18. Remove cylinder head
19. 19. Removing balancer shaft unit
20. 20. Mark order of con-rod bearing caps (3)

Note. Con-rod bearing cap bead (4) points to transmission side

21. 21. Remove con-rod bearing cap from con-rod
22. 22. Remove combustion residue from upper part of cylinder bore
23. 23. Remove pistons with con-rods from cylinder bore from above
24. 24. Clean and check all parts, replace if necessary

Install

25. 25. Coat piston rings with engine oil and compress with commercially available piston ring compressor.

Important. Installation position: Arrow (1) on piston head points to engine timing side – bead on con-rod points to transmission side

26. 26. Push piston into cylinder bore with hammer shaft. .

27. 27. Note con-rod bearing cap order. Attach con-rod bearing cap to con-rod with new bolts

Note. Con-rod bearing cap bead (1) points to transmission side 35 Nm + 45° + 15°

28. 28. Apply a bead of adhesive sealing compound (black) to joints of oil pump and rear crankshaft bearing cap
29. 29. Install balancer shaft unit
30. 30. Install cylinder head

31. 31. Apply a bead of adhesive sealing compound (black) to joints (arrows) of oil pump and rear crankshaft bearing cap
32. 32. Insert upper part of oil pan (1) with new gasket and oil intake pipe
33. 33. Attach oil intake pipe to oil pump with new seal ring 8 Nm 1)
34. 34. Attach oil intake pipe to balancer shaft unit 10 Nm

35. 35. Attach upper part of oil pan to cylinder block, oil pump and transmission housing with new gasket
36. 36. Insert contact surfaces of bolts (1) coated with surface sealant (green) Installation sequence: 1. Tighten all bolts loosely. 2. Tighten bolts at cylinder block and oil pump 20 Nm 3. Tighten bolts at transmission housing 40 Nm .

37. 37. Insert turbocharger oil feed line (cylinder block) and attach to cylinder block flange with union nut 20 Nm
38. 38. Attach turbocharger oil feed line union nut (cylinder block) to turbocharger oil feed line (turbocharger) 20 Nm
39. 39. Attach turbocharger oil feed line bracket to cylinder block 35 Nm
40. 40. Coat oil filter seal ring with a thin layer of engine oil and attach to oil pump 15 Nm
41. 41. Insert dynamic oil level control plug-in connection into upper section of oil pan with new seal ring and fix in position with retaining ring
42. 42. Attach lower section of oil pan to upper section of oil pan with new gasket and new bolts 8 Nm + 30°
43. 43. Attach oil drain bolt to lower section of oil pan with new gasket 10 Nm
44. 44. Connect wiring harness plug for dynamic oil level control
45. 45. Install front exhaust pipe with new gasket 35 Nm
46. 46. Connect wiring harness plug for catalytic converter control oxygen sensor
47. 47. Route wiring harness

Note. Note routing of wires

48. 48. Install lower engine splash guard
49. 49. Top up engine oil quantity to "MAX" mark on oil dipstick

1

) Recut thread before use and insert bolts with bolt locking compound (red). Installation time including torque check should not exceed 10 minutes.