Replace Piston Rings Opel Meriva A

Remove

1. 1. Remove cylinder head
2. 2. Detach oil baffle plate • Unscrew 6x bolts (1)
3. 3. Set crankshaft to TDC of combustion stroke of cylinder 2

Important. The mating surfaces of the con-rod and the con-rod bearing cap form a unique fit and must not be swapped or damaged. Do not lay down on the mating surfaces

4. 4. Remove con-rod bearing caps (1), cylinders 2 and 3 • Unscrew 4x bolt • Push 2x pistons with con-rods upwards

Note. Pay attention to mark (2) on con-rod and con-rod cap at intake side. Put down in accordance with the removal order.

5. 5. Lower vehicle all the way
6. 6. Remove 2x pistons
7. 7. Raise vehicle all the way
8. 8. Rotate crankshaft 180°
9. 9. Remove con-rod bearing caps, cylinders 1 and 4 • Unscrew 4x bolt • Push 2x pistons with con-rods upwards

Note. Pay attention to mark on con-rod and con-rod cap at intake side. Put down in accordance with the removal order!

Important. The mating surfaces of the con-rod and the con-rod bearing cap form a unique fit and must not be swapped or damaged. Do not lay down on the mating surfaces

10. 10. Lower vehicle all the way
11. 11. Remove 2x pistons
12. 12. Remove 8x con-rod bearing shells

Note. Note removal sequence!

13. 13. Visually check components • Crank drive

Important. Do not damage piston and con-rod. Use protective jaws.

14. 14. Clamp piston (1) with con-rod (3) in vice
15. 15. Detach piston from con-rod • Remove 2x piston pin retaining rings (2) • Remove piston pin (4) – Press piston pin out of piston and con-rod by hand • Remove piston

Note. If replacing pistons and/or con-rods

Important. The maximum inclination at the ring gap must not exceed dimension I ( 28 mm )

16. 16. Detach piston rings • Detach 3x piston rings with piston ring pliers (1)

Note. If replacing piston rings

17. 17. Check piston ring gap clearance with feeler gauge • Insert piston ring into cylinder bore • Permitted gap clearance: – 1st compression ring (1) 0.20 – 0.30 mm – 2nd compression ring (2) 1.00 – 1.50 mm – Oil scraper ring (3) 0.25 – 0.50 mm
18. 18. Check piston ring axial play with feeler gauge in piston ring groove • Permitted axial play: – 1st compression ring (1) 0.09 – 0.13 mm – 2nd compression ring (2) 0.04 – 0.08 mm – Oil scraper ring (3) 0.03 – 0.07 mm

Install

Important. The maximum inclination at the ring gap must not exceed dimension I ( 28 mm )

19. 19. Fit piston rings • Insert 3x piston rings into ring groove with piston ring pliers (1)

Note. Pay attention to marks on piston rings

20. 20. Adjust piston ring gap • Arrange piston ring gaps offset by 120°

Important. When assembling the piston and the con-rod, pay attention to recess in piston (2) and con-rod identification (1)

21. 21. Attach piston to con-rod • Slide piston pin into piston • Place piston with piston pin onto con-rod • Slide piston head into piston through con-rod eye

Note. Coat piston head with engine oil

Note. Ring grooves for piston head retaining rings must be free.

22. 22. Insert 2x piston head retaining rings into piston

Note. Ring gap must be positioned within range of dimension I (maximum 30° )

23. 23. Remove piston with con-rod from vice

Important. Align con-rod bearing shell centrally in the con-rod and con-rod bearing cap.

24. 24. Insert 8x con-rod bearing shells (1) • In con-rod and con-rod bearing cap (2)

Note. Insert con-rod bearing shell with oil bore (3) in con-rod bearing cap.

25. 25. Adjust piston ring gap

Note. Offset piston ring gaps by 120°

Important. Arrow (2) on piston head points towards engine timing side

26. 26. Install pistons in cylinder no.1 and cylinder no.4 • Coat 2x pistons and cylinder bores with engine oil • Compress 2x piston rings with piston tensioning strap • Slide 2x pistons into cylinders
27. 27. Raise vehicle all the way

Important. Pay attention to assignment and installation position (1)

28. 28. Attach con-rod bearing cap to cylinder 1 and 4 • Use new bolts • Coat 2x con-rod bearing journals with engine oil • Tighten 4x new bolts 20 Nm + 40°

29. 29. Rotate crankshaft by 180°
30. 30. Lower vehicle all the way
31. 31. Install pistons in cylinder no.2 and cylinder no.3
32. 32. Attach oil baffle plate • Tighten 6x bolts 9 Nm
33. 33. Install cylinder head