Opel Insignia: Pistons, Connecting Rods & Bearings

RIDGE REMOVAL

NOTE: Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

Ridge in cylinder wall must be removed prior to piston removal. Failure to remove ridge prior to removing pistons will cause piston damage in piston ring lands or grooves.

With piston at bottom dead center, place rag in bore to trap metal chips. Install ridge reamer in cylinder bore. Adjust ridge reamer using manufacturer's instructions. Remove ridge using ridge reamer. DO NOT remove an excessive amount of material. Ensure ridge is completely removed.

PISTON & CONNECTING ROD REMOVAL

NOTE: Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

Note top of piston. Some pistons may contain a notch, arrow or be marked FRONT. Piston must be installed in proper direction to prevent damage with valve operation.

Check that connecting rod and cap are numbered for cylinder location and which side of cylinder block the number faces. Proper cap and connecting rod must be installed together. Connecting rod cap must be installed on connecting rod in proper direction to ensure bearing lock procedure. Mark connecting rod and cap if necessary. Pistons must be installed in original location.

Remove cap retaining nuts or bolts. Remove bearing cap. Install tubing protectors on connecting rod bolts. This protects cylinder walls from scoring during removal. Ensure proper removal of ridge. Push piston and connecting rod from cylinder. Connecting rod boss can be tapped with a wooden dowel or hammer handle to aid in removal.

PISTON & CONNECTING ROD

NOTE: Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Descriptions of processes of cleaning, inspection, assembly and machine shop practice are included.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

Disassembly

Using ring expander, remove piston rings. Remove piston pin retaining rings (if equipped). Note direction of piston installation on connecting rod. On pressed type piston pins, special fixtures and procedures according to manufacturer must be used to remove piston pins. Follow manufacturer's recommendations to avoid piston distortion or breakage.

Cleaning

Remove all carbon and varnish from piston. Pistons and connecting rods may be cleaned in cold type chemical tank. Using ring groove cleaner, clean all deposits from ring grooves. Ensure all deposits are cleaned from ring grooves to prevent ring breakage or sticking. DO NOT attempt to clean pistons with wire brush.

Inspection

Inspect pistons for nicks, scoring, cracks or damage in ring areas. Connecting rod should be checked for cracks using Magnaflux procedure. Piston diameter must be measured in manufacturer's specified area.

Using telescopic gauge and micrometer, measure piston pin bore of piston in 2 areas, 90 degrees apart.

This is done to check diameter and out-of-round.

Install proper bearing cap on connecting rod. Ensure bearing cap is installed in proper location. Tighten bolts or nuts to specification. Using inside micrometer, measure inside diameter in 2 areas, 90 degrees apart.

Connecting rod I.D. and out-of-round must be within specification. Measure piston pin bore I.D. and piston pin O.D. All components must be within specification. Subtract piston pin diameter from piston pin bore in piston and connecting rod to determine proper fit.

Connecting rod length must be measured from center of crankshaft journal inside diameter to center of piston pin bushing using proper caliper. Connecting rods must be the same length. Connecting rods should be checked on an alignment fixture for bent or twisted condition. Replace all components which are damaged or not within specification.

PISTON & CYLINDER BORE FIT

NOTE: Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

Ensure cylinder is checked for taper, out-of-round and properly honed prior to checking piston and cylinder bore fit. See CYLINDER BLOCK. Using dial bore gauge, measure cylinder bore.

Measure piston skirt diameter at 90 degree angle to piston pin at specified area by manufacturer.

Subtract piston diameter from cylinder bore diameter to determine piston-to-cylinder clearance.

Clearance must be within specification. Mark piston for proper cylinder location.

ASSEMBLING PISTON & CONNECTING ROD

NOTE: Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Descriptions of processes of cleaning, inspection, assembly and machine shop practice are included.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

Install piston on connecting rod for corresponding cylinder. Ensure reference marking on top of piston corresponds with connecting rod and cap number. See Fig. 14.

Lubricate piston pin and install in connecting rod. Ensure piston pin retainers are fully seated (if equipped). On pressed type piston pins, follow manufacturer's recommended procedure to avoid distortion or breakage.

Fig. 14: Installing Typical Piston Pin

CHECKING PISTON RING CLEARANCES

NOTE: Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

Piston rings must be checked for side clearance and end gap. To check end gap, install piston ring in cylinder in which it is to be installed. Using an inverted piston, push ring to bottom of cylinder in smallest cylinder diameter.

Using feeler gauge, check ring end gap. See Fig. 15. Piston ring end gap must be within specification.

Ring breakage will occur if insufficient ring end gap exists.

Some manufacturers permit correcting insufficient ring end gap by using a fine file while other manufacturers recommend using another ring set. Mark rings for proper cylinder installation after checking end gap.

Fig. 15: Checking Piston Ring End Gap

For checking side clearance, install rings on piston. Using feeler gauge, measure clearance between piston ring and piston ring land. Check side clearance in several areas around piston. Side clearance must be within specification.

If side clearance is excessive, piston ring grooves can be machined to accept oversize piston rings (if available). Normal practice is to replace piston.

PISTON & CONNECTING ROD INSTALLATION

NOTE: Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

Cylinders must be honed prior to piston installation. See CYLINDER HONING under CYLINDER BLOCK.

Install upper connecting rod bearings. Lubricate upper bearings with engine oil. Install lower bearings in rod caps. Ensure bearing tabs are properly seated. Position piston ring gaps according to manufacturer's recommendations. See Fig. 16. Lubricate pistons, rings and cylinder walls.

Fig. 16: Positioning Typical Piston Ring End Gap

Install ring compressor. Use care not to rotate piston rings. Compress rings with ring compressor. Install plastic tubing protectors over connecting rod bolts. Install piston and connecting rod assembly. Ensure piston notch, arrow or FRONT mark is toward front of engine. See Fig. 17.

Fig. 17: Installing Piston & Connecting Rod Assembly

Carefully tap piston into cylinder until rod bearing is seated on crankshaft journal. Remove protectors.

Install rod cap and bearing. Lightly tighten connecting rod bolts. Repeat procedure for remaining cylinders. Check bearing clearance. See MAIN & CONNECTING ROD BEARING CLEARANCE.

Once clearance is checked, lubricate journals and bearings. Install bearing caps. Ensure marks are aligned on connecting rod and cap. Tighten rod nuts or bolts to specification. Ensure rod moves freely on crankshaft. Check connecting rod side clearance. See CONNECTING ROD SIDE CLEARANCE.

CONNECTING ROD SIDE CLEARANCE

NOTE: Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

Position connecting rod toward one side of crankshaft as far as possible. Using feeler gauge, measure clearance between side of connecting rod and crankshaft. See Fig. 18. Clearance must be within specification.

Check for improper bearing installation, wrong bearing cap or insufficient bearing clearance if side clearance is insufficient. Connecting rod may require machining to obtain proper clearance. Excessive clearance usually indicates excessive wear at crankshaft. Crankshaft must be repaired or replaced.

Fig. 18: Measuring Connecting Rod Side Clearance

MAIN & CONNECTING ROD BEARING CLEARANCE

NOTE: Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

Plastigage Method

Plastigage method may be used to determine bearing clearance. Plastigage can be used with an engine in service or during reassembly. Plastigage material is oil soluble.

Ensure journals and bearings are free of oil or solvent. Oil or solvent will dissolve material and false reading will be obtained. Install small piece of Plastigage along full length of bearing journal. Install bearing cap in original location. Tighten bolts to specification.

CAUTION: DO NOT rotate crankshaft while Plastigage is installed. Bearing clearance will not be obtained if crankshaft is rotated.

Remove bearing cap. Compare Plastigage width with scale on Plastigage container to determine bearing clearance. See Fig. 19. Rotate crankshaft 90 degrees. Repeat procedure. This is done to check journal eccentricity. This procedure can be used to check oil clearance on both connecting rod and main bearings.

Fig. 19: Measuring Bearing Clearance

Micrometer & Telescopic Gauge Method

A micrometer is used to determine journal diameter, taper and out-of-round dimensions of the crankshaft. See CLEANING & INSPECTION under CRANKSHAFT & MAIN BEARINGS in this article.

With crankshaft removed, install bearings and caps in original location on cylinder block. Tighten bolts to specification. On connecting rods, install bearings and caps on connecting rods. Install proper connecting rod cap on corresponding rod. Ensure bearing cap is installed in original location. Tighten bolts to specification.

Using a telescopic gauge and micrometer or inside micrometer, measure inside diameter of connecting rod and main bearings bores. Subtract each crankshaft journal diameter from the corresponding inside bearing bore diameter. This is the bearing clearance.

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