How to Replace the Piston Rings Opel Corsa D

Remove

1. 1. Remove cylinder head
2. 2. Raise vehicle by its full height
3. 3. Drain engine oil • Place collecting basin underneath. • Unscrew drain bolt
4. 4. Remove oil pan • from transmission – Unscrew 3x bolts (2) • Cylinder block base plate – Unscrew 16x bolts (1)

5. 5. Remove KM-952
6. 6. Detach con-rod bearing caps (1) from cylinder 2 and 3 • Mark order of con-rod bearing caps • Unscrew 4x bolts • Take out 4x con-rod bearing caps • Push piston with con-rod upwards

Note. The mating surfaces of the con-rods and con-rod bearing caps form an individual fit and should never be swapped over or damaged. To avoid damage, do not put the con-rods and con-rod bearing caps down on the mating surfaces.

Note. Note installation position, bead (arrow) on the con-rod bearing cap points towards the transmission side.

7. 7. Lower vehicle by its full height
8. 8. Take 2x piston with con-rod out of cylinder block
9. 9. Turn crankshaft • Pull timing chain upwards • Turn crankshaft 180°
10. 10. Detach con-rod bearing caps (1) from cylinder 1 and 4 • Mark order of con-rod bearing caps • Unscrew 4x bolts • Take out 4x con-rod bearing caps • Push piston with con-rod upwards

Note. The mating surfaces of the con-rods and con-rod bearing caps form an individual fit and should never be swapped over or damaged. To avoid damage, do not put the con-rods and con-rod bearing caps down on the mating surfaces.

Note. Note installation position, bead (arrow) on the con-rod bearing cap points towards the transmission side

Install

11. 11. Clean and check all the components, replace if necessary

Note. Pistons may only be replaced in conjunction with con-rod and piston pin.

12. 12. Insert con-rod bearing shells into con-rods and con-rod bearing caps • Coat with engine oil
13. 13. Check piston ring vertical play with feeler gauge in piston ring groove. • Rectangular compression ring (1) • Tapered compression ring (2) • Oil scraper ring (3)

14. 14. Install piston rings • Insert piston rings in ring groove using piston ring pliers – Marking "TOP" at the top
15. 15. Set piston ring gap • First piston ring (right-hand ring) in position (1) • Second piston ring (minute ring) in position (4) • Interim ring of oil scraper ring in position (5), steel band rings of oil scraper ring in position (2) and/or (3)

16. 16. The bead (1) on the con-rod points towards the transmission side

17. 17. Install piston of cylinder 1 and 4 • Coat pistons and cylinder bores with engine oil • Push piston rings together with piston tightening strap • Push piston into cylinder bore with hammer shaft until con-rod sits on the con-rod bearing journal of the crankshaft

Note. Arrow (1) on the piston head points to engine timing side – bead (2) on the con-rod points to transmission side.

18. 18. Raise vehicle by its full height
19. 19. Install con-rod bearing cap • Wet con-rod bearing journal with engine oil • Use new bolts • Tighten 4x bolts 13 Nm + 60° + 15°

Note. Bead on con-rod bearing cover points towards gearbox side.

Important. Only use bolts of size M6.5.

20. 20. Lower vehicle by its full height
21. 21. Turn crankshaft • Pull timing chain upwards • Turn crankshaft 180°
22. 22. Install piston of cylinder 2 and 3 • Coat pistons and cylinder bores with engine oil • Push piston rings together with piston tightening strap • Push piston into cylinder bore with hammer shaft until con-rod sits on the con-rod bearing journal of the crankshaft

Note. Arrow (1) on the piston head points to engine timing side – bead (2) on the con-rod points to transmission side.

23. 23. Raise vehicle by its full height
24. 24. Install con-rod bearing cap • Wet con-rod bearing journal with engine oil • Use new bolts • Tighten 4x bolts 13 Nm + 60° + 15°

Note. Bead on con-rod bearing cover points towards gearbox side.

Important. Only use bolts of size M6.5.

25. 25. Install oil pan with new gasket • Screw in 19x bolts • Tighten 16x bolt on cylinder block base plate 10 Nm • Tighten 3x bolt on transmission 40 Nm

Note. Comply with the following tightening sequence.

26. 26. Attach oil drain bolt to oil pan • Use new seal ring • Tighten drain bolt 10 Nm
27. 27. Lock crankshaft • Insert KM-952 • Pull timing chain upwards • Turn crankshaft evenly until KM-952 engages
28. 28. Lower vehicle by its full height
29. 29. Install cylinder head