Opel Frontera UE. Manual - part 883

6A–81

ENGINE MECHANICAL (6VD1 3.2L)

Piston and Connecting Rod

Piston, Connecting Rod and Associate Parts

015RW019

Legend

(1) Cylinder Head Assembly
(2) Cylinder Head Gasket
(3) Crankcase with Oil Pan
(4) Oil Pipe and O-Ring
(5) Oil Strainer and O-Ring
(6) Oil Gallery

(7) Piston and Connecting Rod Assembly
(8) Piston Ring
(9) Piston Pin

(10) Piston

(11) Connecting Rod

(12) Connecting Rod Cap

Disassembly

1. Remove cylinder head assembly (1). Refer to

“Cylinder Head Removal” in this manual.

2. Remove cylinder head gasket (2).
3. Remove crankcase with oil pan (3). Refer to“Oil Pan

and Crankcase” in this manual.

4. Remove oil pipe and O-ring (4).

5. Remove oil strainer and O-ring (5).
6. Remove oil gallery (6).
7. Remove connecting rod cap with connecting rod

lower bearing (12).

8. Remove piston and connecting rod assembly (7).

NOTE: Before removing piston and connecting rod
assembly, measure thrust clearance.

6A–82

ENGINE MECHANICAL (6VD1 3.2L)

015RS031

D

Remove any ridge or carbon build up from the top
end of the cylinder.

9. Remove the piston rings (8) with a piston ring

expander. Arrange the removed piston rings in the
cylinder number order.

015RS022

10. Remove the piston pin (9) using 5–8840–0551–0

piston pin service set and piston support with a press.

NOTE: Keep the parts removed from each cylinder
separate.  All parts must be reinstalled in their original
positions.  Heating the connecting rod will permit easy
removal of the piston pin.

015RX001

Legend

(1) Press Ram
(2) Piston
(3) Connecting Rod
(4) Piston Pin

11. Piston (10)

12. Connecting rod (11)

Inspection and Repair

Pistons

Carefully clean away all the carbon adhering to the piston
head and the piston ring grooves.

NOTE: Never use a wire brush to clean the pistons.
Damage will result. Visually check each piston for
cracking, scoring, and other signs of excessive wear. If
any of the above conditions are found, the piston must be
replaced.

Piston Diameter

1. Measure the piston outside diameter with micrometer

at the piston grading position and a right angle to the
piston pin.
Piston grading position (from piston head)

Piston grading position : 43.0 mm (1.6929 in)

6A–83

ENGINE MECHANICAL (6VD1 3.2L)

015RV014

The size mark (1) for piston outside diameter is
represented as shown in illustration below.

Outside Diameter
Size Mark A : 93.360 mm–93.370 mm

(3.6756 in–3.6760 in)

Size Mark B : 93.371 mm–93.380 mm

(3.6760 in–3.6764 in)

Size Mark C : 93.381 mm–93.390 mm

(3.6764 in–3.6768 in)

015RX002

Measure the cylinder bore inside diameter (refer to
“Cylinder Block” in this manual).

012RS002

Piston Rings

Any worn or damaged part discovered during engine
overhaul must be replaced with a new one.

1. Ring end gap measurement

D

Insert the piston ring into the bore.

D

Push the ring by the piston, at a right angle to the
wall, into the point at which the cylinder bore
diameter is the smallest.

D

Measure the ring end gap.

Compression Ring

1st ring

Standard:

0.300 mm–0.400 mm

(0.0118 in–0.0157 in)

Limit:

1.0 mm (0.0394 in)

2nd ring

Standard:

0.450 mm–0.600 mm

(0.0177 in–0.0236 in)

Limit:

1.2 mm (0.0472 in)

Oil ring

Standard:

0.150 mm–0.450 mm

(0.0059 in–0.0177 in)

Limit:

1.05 mm (0.0413 in)

6A–84

ENGINE MECHANICAL (6VD1 3.2L)

015RS026

D

Positioning mark (1) is painted as shown in the
illustration.

Marked T : No.1 Compression ring

Marked T2 : No.2 Compression ring

015RS027

2. Measure the clearance between the piston ring

groove and the piston ring with a feeler gauge. If the
piston ring groove / piston ring clearance exceeds the
specified limit, the piston must be replaced.

Compression Ring Clearance
Standard : 0.016 mm–0.038 mm

(0.0006 in.–0.0015 in)

Limit : 0.15mm (0.0059 in)

015RS028

Piston Pin

NOTE: Do not reuse the old piston pin.

1. Use a micrometer to measure the new piston pin

outside diameter in both directions at three different
positions.

2. Measure the inside diameter of the connecting rod

small end. If the fitting interference between the small
end and pin does not conform to the specified value,
the connecting rod must be replaced.

Standard : 0.023 mm–0.038 mm (0.0009
in–0.0015 in)

015RS029

3. Insert the new pin into the piston and rotate it. If the

pin rotates smoothly with no backlash, the clearance
is normal. If there is backlash or roughness, measure
the clearance. If the clearance exceeds the specified
limit, the piston must be replaced.

Clearance
Standard : 0.010 mm–0.017 mm

(0.0004 in.–0.0007 in)

Limit : 0.040 mm (0.0016 in)