GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Opel 🢒 2009 🢒 Insignia HB (Global Epsilon) 🢒 Engine 🢒 Engine Mechanical - 1.6L (LDE or LLU) and 1.8L (2H0) 🢒 Piston, Connecting Rod, and Bearing Removal

    Object Number: 1948709 Size: SH
  1. Install the torsional vibration dampener bolt into the crankshaft and set pistons 1 and 4 to bottom dead center (BDC) in the direction of engine rotation.

    2. Note: Note the cylinder sequence.

  2. Mark the connecting rod with the connecting rod bearing cover (1).

    3. Object Number: 1937053 Size: SH
  3. Unscrew pistons 1 and 4.
    4. 3.1. Remove the 2 connecting rod bearing caps (1).
    3.2. Remove the 4 bolts.

    Object Number: 1937036 Size: SH
  4. Push the 2 pistons, with connecting rods, out of the cylinder bore.

    5. Note: The shear surfaces of the connecting rod and the connecting rod bearing cover form a unique fit and must not be swapped or damaged. DO NOT lay down on the shear surfaces.

  5. Remove pistons 1 and 4.
  6. Turn the crankshaft on the torsional vibration balancer through 180 degrees in the direction of engine rotation.

    7. Object Number: 1948709 Size: SH

    Note: Note the cylinder sequence.

  7. Mark the connecting rod with connecting rod bearing cover (1).

    8. Object Number: 1937048 Size: SH
  8. Unscrew pistons 2 and 3.
    9. 8.1. Remove the 2 connecting rod bearing caps (1).
    8.2. Remove the 4 bolts.

    Object Number: 1937040 Size: SH
  9. Push the 2 pistons, with connecting rods, out of the cylinder bore.

    10. Note: 

       • The shear surfaces of the connecting rod and the connecting rod bearing cover form a unique fit and must not be swapped or damaged. Do not lay down on the shear surfaces.
       • Clean and visually inspect all components.

  10. Remove pistons 2 and 3.

    11. Object Number: 1948710 Size: SH

    Note: Observe the correct fitting position and alignment.

  11. Remove the connecting rod bearing mounting clips (1, 2).
  12. Visually inspect the components.