Opel 1900 1973, Service Manual

Page: 585 / 625

1973 OPEL SERVICE MANUAL
race. If, for example a feeler gage reading of 0.009
inch results, a thrust race with a number
stamped on it should be selected.
Thrust Race Table
SERVICE ID NO.
PART NO. ON RACE
NESS
6556000 0
6556050
5
6556055 5
6556060 6
6556065 6
6556070 7
6556075 7
6556080 8
6556085 8
6556090
6556095
9
6556100
10
6556105 10
6556110
6556115
6556120
1 2
The selected thrust race will replace only the “zero”
outer rear thrust race. The remaining three “zero”
thrust races will remain as part of the cylinder assem-
bly.
13. Remove cylinder assembly from inside compress-
ing fixture (J-9397), place on top of compressing
fixture (see Figure
and disassemble rear cyl-
inder from front cylinder using rubber mallet or
hammer and wood block.
14. Carefully disassemble one piston at a time from
front cylinder and lay piston, front and rear piston
drive balls and front “zero” shoe disc in respective
slot of parts tray (J-9402). To disassemble, rotate
plate until piston is at highest point, raise a
plate approximately
inch and lift out pis-
ton and related parts, one at a time.
15. Remove outer rear thrust race from shaft
and set it aside for future gaging procedures.
16. Remove previously selected outer rear thrust
race from parts tray, lightly coat with clear pe-
troleum jelly and assemble onto shaft.
Final Reassembly of Cylinder Assembly
1. Reassemble piston rings (if service pistons) onto
pistons (ring scraper groove toward center of piston)
and rotate ring so that break or gap in ring can be
squeezed together when piston is being inserted into
cylinder bore.
2. Reassemble piston drive balls, “zero” and se-
lected shoe discs onto No. piston, and apply
clear petroleum jelly to piston pockets and shoe discs
so that balls and discs stick to piston. BE SURE to
reassemble balls and shoe discs into their specific
positions on front and rear of piston.
3. Rotate shaft and plate assembly until high
point of plate is over No. “1” cylinder bore.
Position No. “1” piston onto plate (see Figure
and lower the piston and plate so that
the front end (notched end) of the piston enters the
cylinder bore.
OUTER
/REAR ZERO
THRUST RACE
PISTON RING
GAP SHOULD BE
T O W A R D
Figure Installing Piston Assembly in Front
Half Service Pistons Shown
Figure Compressing Front Piston Rings
Service Pistons