Vauxhall/Opel Special Tool Is Required To Set Tdc Position; Vauxhall/Opel Special Tool To Set The Camshaft Position; Undo Central Mounting Bolt And Remove Drivebelt Tensioner Assembly; Undo Retaining Bolts And Remove Right-Hand Engine Mounting - Opel Zafira B MPV 2006 Owners Workshop Manual

20•4 1.9 litre DOHC diesel engine in-car repair procedures
3.0a Vauxhall/Opel special tool EN-46788
(or equivalent) is required to set the TDC
position for No 1 piston •••
because there is
a
risk that the oil will sit in
the recess on the piston crown instead of
passing to the rings.
8 On completion of the test, refit the fuel pump
relay, then refit the glow plugs as described in
Chapter SA.
Leakdown
test
9 A leakdown test measures the rate at which
compressed air fed into the cylinder is lost. It
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.
3.8 Undo the retaining bolts and remove
the right-hand engine mounting
3.10 Undo the bolt (arrowed) and release
the engine oil dipstick guide tube from the
coolant pipe
3.0b ••• together with Vauxhall/Opel
special tool EN-46789 (or equivalent) to set
the camshaft position
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 equivalent) to set the crankshaft at
the TDC position, together with the camshaft
positioning tool, Vauxha/1/0pel special tool
EN-46789 (or suitable equivalent) (see
illustrations).
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
3.9 Engine breather pipe retaining bolts
(arrowed)
3.11 Unscrew the closure bolt from the
valve timing checking hole in the camshaft
housing
3.5 Undo the central mounting bolt
(arrowed), and remove the auxiliary
drivebelt tensioner assembly
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 Disconnect the battery negative terminal
(refer to Disconnecting the battery in the
Reference Chapter), then lift off the plastic
cover over the top of the engine.
4 Remove the crankshaft pulley/vibration
damper as described in Section 5.
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 Release the retaining clip securing the
engine breather hose to the breather pipe
adjacent to the engine oil dipstick. Undo the
two bolts securing the breather pipe to the
cylinder head, and disconnect the pipe from
the hose (see illustration).
10 Undo the bolt and release the engine oil
dipstick guide tube from the coolant pipe (see
illustration).
11 Unscrew the closure bolt from the valve
timing checking hole in the camshaft housing
(see illustration).
12 Screw the camshaft positioning tool
(Vauxhall/Opel special tool EN-46789) into the
valve timing checking hole.
13 Using a socket and extension bar on the
crankshaft sprocket bolt, rotate the crankshaft
in the normal direction of rotation until the
spring-loaded plunger of the positioning tool
slides into engagement with the slot in the
camshaft. There will be an audible click from
the tool when this happens.
14 Unscrew the bolt from the lower left-hand