Piston/Connecting Rods; Press Bearing Shells Into Connecting Rods And Caps; Piston Ring End Gap Positions; Ensure Piston Ring End Gaps Are Correctly Spaced, Fit Ring Compressor - Opel Zafira B MPV 2006 Owners Workshop Manual

18.2 Press the bearing shells into the
connecting rods and caps in their correct
positions
a gauge is not available, use white paint to
make alignment marks between the bolt head
and cap prior to tightening; the marks can
then be used to check that the bolt has been
rotated through the correct angle.
38 Check that the crankshaft is free to rotate
smoothly; if excessive force is required to turn
the crankshaft, investigate the cause before
proceeding further.
39 Check the crankshaft endfloat with
reference to Section 10.
40 Refit/reconnect the piston connecting rod
assemblies to the crankshaft as described in
Section 18.
41
Referring to Part C or D (as applicable) of
this Chapter, fit a new left-hand crankshaft oil
seal/housing, then refit the oil pump, sump,
flywheel/driveplate, cylinder head, timing belt
sprocket(s) and fit a new timing belt.
Note:
It is recommended that new big-end
bearing shells are fitted regardless of the
condition of the original ones.
1 Clean the backs of the big-end bearing
shells and the recesses in the connecting
rods and big-end caps. If new shells are being
fitted, ensure that all traces of the protective
grease are cleaned off using paraffin. Wipe the
shells, caps and connecting rods dry with a
lint-free cloth.
2 Press the bearing shells into their locations,
ensuring that the tab on each shell engages in
the notch in the connecting rod and cap (see
illustration).
If there is no tab on the bearing
shell (and no notch in the rod or cap) position
the shell equidistant from each side of the rod
and cap. If the original bearing shells are being
used ensure they are refitted in their original
locations.
3 Lubricate the bores, the pistons and piston
rings then lay out each piston/connecting rod
assembly in its respective position.
Petrol engines
4 Lubricate No 1 piston and piston rings,
and check that the ring gaps are correctly
positioned. The gaps in the upper and lower
Engine removal and overhaul procedures 2E•17
I
18.4 Piston ring end gap positions -
petrol engines
I Top and second compression rings
JI Oil control ring side rails
steel rings of the oil control ring should be
offset by 25 to 50 mm to the right and left
of the spreader ring gap. The two upper
compression ring gaps should be offset by
180° to each other (see illustration).
5 Fit a ring compressor to No 1 piston, then
insert the piston and connecting rod into
the cylinder bore so that the base of the
compressor stands on the block. With the
crankshaft big-end bearing journal positioned
at its lowest point, tap the piston carefully
into the cylinder bore with the wooden handle
of a hammer, and at the same time guide
the connecting rod onto the bearing journal.
Note that the arrow on the piston crown must
point towards the timing chain/belt end of the
engine (see illustrations).
6 Liberally lubricate the bearing journals and
bearing shells, and fit the bearing cap in its
original location (the lug on the bearing cap
base should be facing the flywheel/driveplate
end of the engine).
7
Screw in the new bearing cap retaining
bolts, and tighten both bolts to the specified
Stage 1 torque setting then tighten the
bolts through the specified angles. It is
recommended that an angle-measuring
gauge is used during the final stages of the
tightening, to ensure accuracy. If a gauge
is not available, use white paint to make
alignment marks between the bolt head and
cap prior to tightening; the marks can then be
18.5c Tap the piston gently into the bore
using handle of a hammer - petrol engines
18.5a Ensure the piston ring end gaps
are correctly spaced then fit the ring
compressor - petrol engines
18.5b Ensuring the arrow on the piston
crown (circled) is pointing towards the timing
belt/chain end of the engine - petrol engines
used to check that the bolt has been rotated
through the correct angle.
8 Refit the remaining three piston and
connecting rod assemblies in the same way.
9 Rotate the crankshaft, and check that it
turns freely, with no signs of binding or tight
spots.
10 Refit the oil pump pick-up/strainer, sump
and the cylinder head as described in Part A
or B (as applicable) of this Chapter.
Diesel engines
11
Lubricate No 1 piston and piston rings,
and space the ring gaps uniformly around the
piston at 120° intervals
(see illustration).
Ill
18.11 Piston ring end gap positions -
diesel engines
I Top compression ring
II Second compression ring
/JI Oil control ring