Replacing pistons with connecting rods (Opel Insignia A)

Removal

1. Install the crankshaft pulley bolt.

2. Set the pistons of the first and fourth cylinders to the top dead center position by turning the crankshaft in the direction of normal rotation.

3. Place a mark on the connecting rod and connecting rod cap (1).

Note: Note the cylinder ordinal number.

4. Unscrew the four connecting rod bolts (2) of the first and fourth cylinders.



5. Remove the connecting rod caps (1) with the lower connecting rod bearings (3).

6. Push the pistons with connecting rods (1) out of the openings of the first and fourth cylinders (2).

Note: The connecting rod and cap joint surfaces form a unique joint and must not be damaged or replaced. Do not drop connecting rods or caps.

7. Turn the crankshaft 180° in the direction of engine rotation.

8. Place a mark on the connecting rod and connecting rod cap (1).

Note: Note the cylinder ordinal number.

9. Unscrew the four connecting rod bolts (2) of the first and fourth cylinders.



10. Remove the connecting rod caps (1) with the lower connecting rod bearings (3).

11. Push the pistons with connecting rods (1) out of the openings of the second and third cylinders (2).

Note: The connecting rod and cap joint surfaces form a unique joint and must not be damaged or replaced. Do not drop connecting rods or caps.

12. Remove the connecting rod bearings (1) and (2).

Note: Do not confuse the upper and lower connecting rod bearings.

(Text copied from an internet website: «OPELBOOK»)

13. Check the condition of all parts.

Installation

1. Lubricate the piston rings, pistons, cylinder bores and piston ring compressor with clean engine oil.

2. Using the device, compress the piston rings and insert the piston assembly with the connecting rod and upper connecting rod bearing (4) into the cylinder.



3. Insert the lower connecting rod bearing (3) and install the connecting rod cover (1).

4. Install new connecting rod bolts (2) and tighten to 35 Nm, then tighten another 45°.

Note: Install the connecting rod caps onto the connecting rods according to the marks.

5. Turn the crankshaft so that the connecting rod bolts are most accessible.