How to Replace the Pistons Opel Meriva A

Note. Pistons removed

Remove

1. 1. Remove 3x piston ring • With piston ring pliers (1) • Remove spiral-type expander

2. 2. Clean ring grooves

Note. Remove carbon remains in piston ring groove using a broken, ground-down piston ring.

3. 3. Measure gap • Insert 3x new piston rings into cylinder • Measure gap with feeler gauge Piston Rings Permissible ring gap 1st compression ring (T) 0.25 - 0.35 mm 2nd compression ring (2T) 0.20 - 0.30 mm Oil scraper ring 0.20 - 0.40 mm Size marks of compression rings 1st ring 2nd ring Standard None None Oversize 0.50 m 50 50 Oversize 1.00 mm 100 100 Size marks of oil scraper rings Standard None Oversize 0.50 m blue Oversize 1.00 mm yellow

Note. Permitted piston ring gaps

4. 4. Measure vertical play • Insert piston rings in piston ring groove – 1st compression ring (T) – 2. Compression ring (T2) – Oil scraper ring • Measure vertical play with feeler gauge

Note. Observe marks on the compression rings.

Note. Permitted vertical play

5. 5. Detach piston (4) from con-rod (5) • Clamp con-rod • Remove retaining ring (1) • Press out piston pin (2)

Note. Use vice jaw protectors.

6. 6. Attach piston rings and oil scraper ring • Clamp piston

Note. Use vice jaw protectors.

Install

7. 7. Install piston rings • Install spiral-type expander of oil scraper ring into piston ring groove • Install oil scraper ring • Install compression rings – 1st compression ring (T) – 2. Compression ring (T2)

Note. Observe marks on the compression rings.

8. 8. Attach piston • Marks on piston head (1) and con-rod (2) face each other • Press in piston pin • Coat piston pin with engine oil • Install new retaining rings (1)

Note. Observe position of ring gap - ring gap must be within range of dimension I (max. 30 °).

9. 9. Install new retaining rings (1)

Note. Observe position of ring gap - ring gap must be within range of dimension I (max. 30 °).