Top Dead Centre For No 1 Piston; Release The Hose Support Clip; Lift Off The Plastic Cover Over The Top Of The Engine; Undo Central Bolt And Remove Auxiliary Drivebelt Tensioner Assembly - Opel Zafira B MPV 2006 Owners Workshop Manual

2C•4 1.9 litre SOHC diesel engine in-car repair procedures
3.0 Vauxhall/Opel special tool EN-46788
(or equivalent) is required to set the TDC
position for No 1 piston
3.3c ••• release the hose support clip ..•
is an alternative to a compression test, and in
many ways it is better, since the escaping air
provides easy identification of where pressure
loss is occurring (piston rings, valves or head
gasket).
10 The equipment needed for leakdown
testing is unlikely to be available to the home
mechanic. If poor compression is suspected,
have the test performed by a Vauxhall/Opel
dealer, or suitably-equipped garage.
Note: To accurately determine the TDC
position for No 1 piston, it will be necessary
to use Vauxha/1/0pel special tool EN-46788 (or
suitable equivalents) to set the crankshaft at
the TDC position (see illustration).
3.8 Undo the retaining bolts and remove
the right-hand engine mounting
3.3a Remove the engine oil filler cap •••
3.3d ••• then lift off the plastic cover over
the top of the engine
1
In its travel up and down its cylinder bore,
Top Dead Centre (TDC) is the highest point
that each piston reaches as the crankshaft
rotates. While each piston reaches TDC both
at the top of the compression stroke and
again at the top of the exhaust stroke, for the
purpose of timing the engine, TDC refers to
the piston position of No 1 cylinder at the top
of its compression stroke.
2 Number 1 piston (and cylinder) is at the
right-hand (timing belt) end of the engine, and
its TDC position is located as follows. Note
that the crankshaft rotates clockwise when
viewed from the right-hand side of the car.
3 Remove the engine oil filler cap, undo the
two retaining bolts, release the hose support
clip, then lift off the plastic cover over the top
of the engine (see illustrations). Refit the oil
filler cap.
4 Remove the crankshaft pulley/vibration
damper as described in Section 6.
3.9 Upper timing belt cover retaining bolts
(arrowed)
3.3b ••. undo the two retaining bolts
(arrowed) •.•
3.5 Undo the central mounting bolt
(arrowed), and remove the auxiliary
drivebelt tensioner assembly
5 Undo the central mounting bolt, and remove
the auxiliary drivebelt tensioner assembly from
the engine (see illustration).
6 Remove the air cleaner assembly and air
intake duct as described in Chapter 48.
7 Place a trolley jack beneath the right-hand
end of the engine with a block of wood on the
jack head. Raise the jack until it is supporting
the weight of the engine.
8 Mark the bolt positions for correct refitting,
then undo the three bolts securing the
right-hand engine mounting to the engine
bracket, and the three bolts securing the
mounting to the body. Remove the mounting
(see illustration).
9 Unclip the wiring harness from the top and
side of the upper timing belt cover. Unscrew
the six retaining bolts and lift off the upper
timing belt cover (see illustration).
10 Using a socket and extension bar on the
crankshaft sprocket bolt, rotate the crankshaft
3.1 O Rotate the crankshaft to align the
mark on the camshaft sprocket (arrowed)
with the pointer on the camshaft cover