1.9 Litre Dohc Diesel Engine In-Car Repair Procedures - Opel Zafira B MPV 2006 Owners Workshop Manual

Chapter 2 Part D:
1 .9 litre DOHC diesel engine
in-car repair procedures
Contents
Section number
Camshafts - removal, inspection and refitting .................. 1 O
Camshaft followers and hydraulic tappets - removal, inspection and
refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Camshaft housing - removal and refitting . . . . . . . . . . . . . . . . . . . . . 9
Camshaft oil seal - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Compression and leakdown tests - description and interpretation. . 2
Crankshaft oil seals - renewal . . . . . . . . . . . .................. 16
Crankshaft pulley/vibration damper - removal and refitting . . . . . . 5
Cylinder head - removal and refitting. . . . . . . . . ............... 12
Engine oil and filter renewal ..................... See Chapter 1 B
Engine oil level check ........................ See Weekly checks
Degrees of difficulty
Section number
Engine/transmission mountings - inspection and renewal ........ 18
Flywheel/driveplate - removal, inspection and refitting .......... 17
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Oil filter housing - removal and refitting. . . . . . . . . . . . . . . . . . . . . . 15
Oil pump- removal, overhaul and refitting ..................... 14
Sump - removal and refitting ............................... 13
Timing belt - removal and refitting. . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Timing belt sprockets, tensioner and idler pulley - removal and
refitting.............................................. 7
Top dead centre (TDC) for No 1 piston - locating . . . . . . . . . . . . . . . 3
Valve timing - checking and adjustment . . . . . . . . . . . . . . . . . . . . . . 4
Easy, suitable for
novice with little
experience
~
I
Fairly easy, suitable~
I
Fair1y difficult,
~
I
Difficult, suitable
~
I
Very difficult,
~
~
for beginner with
~
suitable for competent~ for experienced DIY
§
suitable for expert
§
~
some experience
~
DIY mechanic
~
mechanic
~
DIY or professional
~
Specifications
General
Engine type .................................... .
Manufacturer's engine code ................................. .
Bore ................................................... .
Stroke .................................................. .
Capacity ............................................... .
Compression ratio ........................................ .
Firing order. . . . . . . . . . . . . . . . . . . . . . ....................... .
Direction of crankshaft rotation .............................. .
Compression pressures
Four-cylinder, in-line, water-cooled. Double overhead camshaft,
belt-driven
Z19DTH
82.0 mm
90.4 mm
1910 cc
17.5:1
1-3-4-2 (No 1 cylinder at timing belt end of engine)
Clockwise (viewed from timing belt end of engine)
Maximum difference between any two cylinders. . . . . . . . . . . . . . . . . . 1.5 bar
lubrication system
Minimum oil pressure at 100°C .............................. .
Oil pump type. . . . . . . . . . . . . . . . . . . . . . . . . . ............... .
1.0 bar at idle speed
Rotor-type, driven by crankshaft pulley/vibration damper from
crankshaft