Undo Three Retaining Bolts And Remove The Oil Filler Housing; Slacken Intake Camshaft Drive Gear Retaining Bolt; Exhaust Camshaft Drive Gear Retaining Bolt; Unscrew And Remove Two Previously-Slackened Retaining Bolts - Opel Zafira B MPV 2006 Owners Workshop Manual

10.3 Undo the three retaining bolts and
remove the oil filler housing
10.12a Unscrew and remove the two
previously-slackened retaining bolts ...
completely, the retaining bolts for the camshaft
drive gears and sprocket should be slackened
as follows.
6 Remove the exhaust camshaft positioning
tool from the valve timing checking hole.
7 It will be necessary to hold the camshaft
sprocket to enable the drive gear and sprocket
retaining bolts to be slackened. Vauxhall
special tools EN-46787 and KM-956-1
are available for this purpose, however, a
home-made tool can easily be fabricated
(see
Tool Tip in Section 7).
8 Working through the oil filler housing
aperture, and using the holding tool to prevent
rotation of the camshaft, slacken the intake
camshaft drive gear retaining bolt. Working
through the vacuum pump aperture, slacken
the exhaust camshaft drive gear retaining bolt
in the same way (see illustrations).
9 Again, using the holding tool, slacken the
camshaft sprocket retaining bolt.
10
Continue with the camshaft housing
removal procedure as described in Section 9,
paragraphs 9 to 11.
11 With the camshaft housing placed upside
down on the bench, unscrew and remove
the previously-slackened retaining bolt, and
remove the timing belt sprocket from the
exhaust camshaft.
12
At the other end of the housing, unscrew
and remove the two previously-slackened
retaining bolts, and lift off the drive gears
from the intake and exhaust camshafts
(see
illustrations).
13
Carefully prise out the exhaust camshaft
oil seal with a screwdriver or similar hooked
1.9 litre DOHC diesel engine in-car repair procedures 20•11
10.Sa Slacken the intake camshaft drive
gear retaining bolt .••
10.12b ... then lift out the exhaust
camshaft drive gear ...
tool. Carefully withdraw the exhaust camshaft
out from the timing belt end of the camshaft
housing (see illustration).
14
Using a wooden dowel or similar, carefully
tap the end of the intake camshaft toward the
timing belt end of the housing, to release the
blanking cap. Remove the cap, then carefully
withdraw the intake camshaft from the housing
(see illustration).
Inspection
15 Examine the camshaft bearing surfaces
and earn lobes for signs of wear ridges and
scoring. Renew the carnshaft(s) if any of
these conditions are apparent. Examine
the condition of the bearing surfaces in the
camshaft housing. If the any wear or scoring
is evident, the camshaft housing will need to
be renewed.
16
If either camshaft is being renewed, it will
10.13 Withdraw the exhaust camshaft ...
10.Sb ... and the exhaust camshaft drive
gear retaining bolt
10.12c ... and the intake camshaft drive
gear
be necessary to renew all the rocker arms and
tappets for that particular camshaft also (see
Section 11 ).
17 Check the condition of the camshaft drive
gears and sprocket for chipped or damaged
teeth, wear ridges and scoring. Renew any
components as necessary.
Refitting
18 Prior to refitting, thoroughly clean all
components and dry with a lint-free cloth.
Ensure that all traces of oil and grease are
removed from the contact faces of the drive
gears, sprocket and camshafts.
19 Lubricate the camshaft bearing journals in
the camshaft housing and carefully insert the
intake and exhaust camshafts.
20
Ensuring that the contact faces are clean
and dry, refit the drive gear to each camshaft.
Note that the gear with the vacuum pump drive
10.14 ... and intake camshaft from the
camshaft housing