Withdraw Each Camshaft Follower; Hydraulic Tappet In Turn, And Place Them In Their Respective Container; Clip The Follower Back Onto The Tappet; Refit Tappet To Its Original Bore - Opel Zafira B MPV 2006 Owners Workshop Manual

5 If any new hydraulic tappets are obtained,
they should be immersed in a container of
clean engine oil prior to refitting.
Refitting
6 Liberally oil the cylinder head hydraulic
tappet bores and the tappets. Working on one
assembly at a time, clip the follower back onto
the tappet, then refit the tappet to the cylinder
head, ensuring that it is refitted to its original
bore. Lay the follower over its respective valve
(see illustrations).
7 Refit the remaining tappets and followers in
the same way.
8 With all the tappets and followers in place,
refit the camshaft housing as described in
Section 9.
Note: New cylinder head bolts will be required
for refitting.
Removal
1 Disconnect the battery negative terminal
(refer to Disconnecting the battery in the
Reference Chapter).
2 Drain the cooling system as described in
Chapter 18.
3 Remove the camshaft housing as described
in Section 9.
4 Remove the camshaft followers and
hydraulic tappets as described in Section 11.
5 Remove the intake and exhaust manifolds
as described in Chapter 48.
6 Release the clips and disconnect the
remaining two coolant hoses at the thermostat
housing, and the coolant hose at the EGR
valve heat exchanger (see illustration).
7 Release the coolant pipe from the stud
at the base of the thermostat housing (see
illustration).
8 Undo the bolt securing the high-pressure
fuel pump mounting bracket to the cylinder
head (see illustration).
9 Make a final check to ensure that all
relevant hoses, pipes and wires have been
disconnected.
10 Working in the reverse of the tightening
sequence (see illustration 12.27), pro-
gressively slacken the cylinder head bolts
by half a turn at a time, until all bolts can be
unscrewed by hand. Note that an M14 Rl8E
socket bit will be required to unscrew the
bolts. Remove the cylinder head bolts and
recover the washers.
11 Engage the help of an assistant, if
necessary, and lift the cylinder head from the
cylinder block (see illustration).
Caution: Do not lay the head on its lower
mating surface; support the head on
wooden blocks, ensuring each block only
contacts the head mating surface.
12 Remove the gasket and keep it for
identification purposes (see paragraph 19).
1.9 litre DOHC diesel engine in-car repair procedures 20•13
11.3a Withdraw each camshaft
follower •.•
11.6a Clip the follower back onto the
tappet •••
13 If the cylinder head is to be dismantled for
overhaul, then refer to Part E of this Chapter.
Preparation for refitting
14 The mating faces of the cylinder head and
12.6 Disconnect the coolant hoses at the
thermostat housing (A), and at the EGR
valve heat exchanger (B)
12.8 Undo the bolt (arrowed) securing the
high-pressure fuel pump mounting bracket
to the cylinder head
11.3b ••. and hydraulic tappet in turn, and
place them in their respective container
11.6b ••• then refit the tappet to its
original bore, and lay the follower over its
respective valve
cylinder block/crankcase must be perfectly
clean before refitting the head. Use a hard
plastic or wood scraper to remove all traces
of gasket and carbon; also clean the piston
crowns. Take particular care, as the surfaces
12.7 Release the coolant pipe from
the stud (arrowed) at the base of the
thermostat housing
12.11 Lift the cylinder head from the
cylinder block